Systems for controlled heating and agitation for liquid food or beverage product creation

ABSTRACT

Systems for controlled heating and/or agitation for liquid food or beverage product creation are disclosed. A dispenser for producing a food or beverage liquid product from a frozen contents in a receptacle includes a chamber configured to hold a receptacle containing the contents and a dilution liquid inlet configured to supply a dilution liquid to the interior of the receptacle. The dispenser also includes a perforator configured to perforate the receptacle and form a product outlet from the receptacle for the liquid product and an agitator configured to impart motion to the receptacle and/or the contents in the receptacle that increases a flow path from the liquid inlet to the product outlet taken by at least a portion of dilution liquid, when supplied, relative to a flow path from the liquid inlet to the product outlet taken by the portion of dilution liquid without the imparted motion.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/389,552, entitled “Systems for Controlled Heating and Agitation forLiquid Food or Beverage Product Creation”, filed Apr. 19, 2019, which isa continuation of and claims priority under 35 U.S.C. § 120 to U.S.patent application Ser. No. 15/352,245, entitled “Systems for ControlledHeating and Agitation for Liquid Food or Beverage Product Creation”,filed Nov. 15, 2016, now U.S. Pat. No. 10,264,912, which is acontinuation of and claims priority under 35 U.S.C. § 120 to U.S. patentapplication Ser. No. 15/347,591, entitled “Systems for and Methods ofControlled Liquid Food or Beverage Product Creation”, filed Nov. 9,2016, now U. S. Pat. No. 10,111,554, which relates to and claimspriority under 35 U.S.C. § 119(e) to U.S. Provisional Patent ApplicationNo. 62/350,928, entitled “Systems for and Methods of Creating LiquidFood and Beverage Product from a Portion-Controlled Receptacle”, filedon Jun. 16, 2016, and U.S. Provisional Patent Application No.62/380,170, entitled “Systems for and Methods of Creating Liquid Foodand Beverage Product from a Portion-Controlled Receptacle”, filed onAug. 26, 2016, and said U.S. patent application Ser. No. 15/347,591 is acontinuation-in-part of and claims priority under 35 U.S.C. § 120 toU.S. patent application Ser. No. 15/265,379, entitled “Systems for andMethods of Agitation in the Production of Beverage and Food Receptaclesfrom Frozen Contents”, filed Sep. 14, 2016, now U.S. Pat. No. 9,615,597,which is a continuation of U.S. patent application Ser. No. 15/185,744,entitled “Systems for and Methods of Providing Support for DisplaceableFrozen Contents in Beverage and Food Receptacles”, filed Jun. 17, 2016,now U.S. Pat. No. 9,487,348, which claims priority under 35 U. S. C. §119(e) to U.S. Provisional Patent Application No. 62/344,212, entitled“Systems for and Methods of Providing Support for Displaceable FrozenContents in Beverage and Food Receptacles”, filed Jun. 1, 2016, and saidU.S. patent application Ser. No. 15/185,744 is a continuation-in-part ofand claims priority under 35 U.S.C. § 120 to U.S. patent applicationSer. No. 15/099,156, entitled “Method of and System for Creating aConsumable Liquid Food or Beverage Product from Frozen Liquid Contents”,filed on Apr. 14, 2016, which is a continuation-in-part of and claimspriority under 35 U. S. C. § 120 to International Patent Application No.PCT/US16/23226, entitled “Method of and System for Creating a ConsumableLiquid Food or Beverage Product from Frozen Liquid Contents”, filed onMar. 18, 2016, which relates to and claims priority under 35 U. S. C. §119(e) to U.S. Provisional Patent Application No. 62/136,072, entitled“Packaging an Iced Concentrate”, filed on Mar. 20, 2015, and U.S.Provisional Patent Application No. 62/275,506, entitled “Method of andSystem for Creating a Consumable Liquid Food or Beverage Product fromFrozen Liquid Contents”, filed on Jan. 6, 2016, and said PCT/US16/23226is a continuation-in-part of and claims priority under 35 U.S.C. § 120to U.S. patent application Ser. No. 14/801,540, entitled “Apparatus andProcesses for Creating a Consumable Liquid Food or Beverage Product fromFrozen Contents”, filed on Jul. 16, 2015, now U.S. Pat. No. 9,346,611,which relates to and claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Patent Application No. 62/136,072, filed Mar. 20, 2015, allof which are incorporated by reference herein in their entirety.

TECHNICAL FIELD

The technical field relates generally to systems for and methods ofcreating liquid food and/or beverage products from frozen contents in acontrolled manner, and in particular to controlling the melting of thefrozen contents into liquid and controlling the vaporization of theliquid into gas.

BACKGROUND

Current or prior machine-based coffee brewing systems and coffee packedin filtered pods allow consumers to produce purportedly fresh-brewedbeverages at the touch of a button while eliminating the need foradditional process steps such as measuring, handling of filters, and/ormessy disposal of used grounds. These machine-based systems typicallyutilize a receptacle that contains dry solids or powders such as drycoffee grinds, tea leaves, or cocoa powder, as well as a filtrationmedia to prevent migration of unwanted solids into the user's cup orglass, and some type of cover or lid. The receptacle itself is oftenthin-walled so it can be perforated with needles or other mechanisms sothat a solvent (e.g., hot water) can be injected into the receptacle. Inpractice, the receptacle is inserted into the machine and, upon closingthe machine's cover, the receptacle is pierced to produce an inlet andan outlet. Thereafter, the hot solvent is delivered to the inlet, addedinto the receptacle, and a brewed beverage exits via a filter to theoutlet.

Such systems often suffer from problems with being able to maintainfreshness of the contents in the receptacle, brew strength from a finitesized package, and/or the inability to conveniently recycle the largenumber of filtered receptacles with spent grinds/leaves created eachyear.

The issue of maintaining freshness can occur, for example, when the drysolid is a finely ground coffee. This issue is largely the result ofunwanted oxidation of critical flavor and aroma compounds in the coffeegrounds, a problem that can be exacerbated by the fact that groundcoffee presents a very large surface area to its ambient environment.While some manufactures may attempt to address this problem using MAP(Modified Atmosphere Packaging) methods (e.g., the introduction of anon-oxidizing gas in place of ambient air), their efforts are oftenlargely unsuccessful for a number of reasons. For example, freshlyroasted whole bean or ground coffee profusely outgases CO₂, thusrequiring a pre-packaging step to allow the grounds to “degas” prior topackaging so the receptacle does not swell or puff outwardly due topressure created from within the receptacle, which in turn would causethe receptacle to take on the appearance of spoiled product. Inaddition, this CO₂ outgassing carries with it and depletes a richmixture of fresh coffee aromas from the ground coffee. Further, coffeebeans and grinds are approximately 44% oxygen by composition, which mayimpact the flavor and fragrance of the coffee internally after theroasting process.

Another downfall of these receptacles that contain dry solids or powdersis often their inability to create a wide range of beverage potency andserving sizes from a given packaging size. A pod that holds ten grams ofground coffee can only produce about two grams of actual brewed coffeecompounds if brewed according to SCAA (Specialty Coffee Association ofAmerica) brewing guidelines. In turn, when two grams of brewed coffeecompounds are diluted in a ten ounce cup of coffee, a concentration ofabout a 0.75 total dissolved solids (TDS) results. TDS (in % throughout)is a measure of the combined content of inorganic and organic substancescontained in a liquid in molecular, ionized or micro-granular colloidalsolids suspended form. Therefore, such a cup of coffee is oftenconsidered a very weak cup of coffee for many consumers. Conversely,some brewers can over-extract the same ten grams of coffee grounds tocreate a higher TDS; however, the additional dissolved solids that areextracted are often harsh on the palate and can ruin the flavorintegrity of the coffee. Soluble/instant coffee is often added to reducethis drawback. In addition, most brewers designed for extracting cannotdeliver pressure and temperature to remove all desired compounds fromthe ground product, therefore often good coffee is wasted, up to 25%,and an often weaker or smaller cup of coffee is produced than desired.

Turning to the matter of recycling, the presence of leftover coffeegrounds, tea leaves and/or other residual waste after brewing (e.g.,spent filters left within the receptacles) typically makes receptaclesunsuitable for recycling. Consumers could remove the cover from thespent receptacles and rinse out the residual material, but this is timeconsuming, messy, a waste of water, and/or a waste of valuable soilnutrients that could otherwise be recycled back into the farmingecosystem. Therefore, most consumers will not bother to recycle inreturn for such an insignificant apparent ecological gain. Recycling canalso be impacted by the type of thermoplastic material used in somereceptacles. For example, in an effort to minimize loss of freshness asdiscussed above, some manufacturers have chosen to use materials thathave exceptional vapor barrier properties, for example, a laminated filmmaterial with an inner layer of ethylene vinyl alcohol (EVOH) copolymer.The combination of different thermoplastic materials in such a laminatedfilm, which could be some combination of EVOH, polypropylene,polyethylene, PVC and/or others material is unsuited to recycling.

Despite the disadvantages above, there still exist a number of differentmachine-based systems on the market today that create beverages fromsingle-serving capsuled products. These have become extremely popularwith consumers, primarily for the convenience they offer in making anacceptable (not necessarily excellent) cup of coffee, often causing theconsumer to swap café quality brewed coffee for the convenience of asingle serving home-brewed cup.

In addition to single serving capsule products, there exist frozenproducts such as coffee extracts and juice concentrates that arecurrently packaged in large containers and cans (e.g., 2 liters) forcreating multiple servings of beverages from a single container.However, it is usually inconvenient and time-consuming to prepare abeverage from these frozen extracts or concentrates. Some coffeeproducts, for example, must be slowly melted prior to use, typicallyover a period of several hours or days. The end product is required tobe stored in a refrigerator thereafter to preserve its product safetywhen less than all servings are consumed. Further, for beverages thatare enjoyed hot, like coffee and tea, the melted extract must then beheated appropriately. Many of these products are not shelf stable, forexample coffee that has a high percentage of solids in the grounds, asthese solids are the result of hydrolyzed wood, which are subject todecomposition and spoilage. Accordingly, the flavor and quality in theselarge batch frozen products can deteriorate in a matter of hours even atrefrigeration temperatures. In addition, the method of forming the finalconsumable beverage is not often not automated and is therefore subjectto over- or under-dilution, leading to an inconsistent user experience.

SUMMARY

The techniques and systems described herein include integrated systemsthat enable a wider variety of food and beverage products to bedispensed than known portion control brewing systems currentlyavailable. In certain embodiments, the systems include a multi-functionand multi-use dispenser that works in cooperation with multi-contentfrozen receptacles. The receptacles contain previously-preparedconcentrates and extracts in a frozen state in a sealed MAP gasenvironment. Because the food or beverages contained therein aremaintained in a preserved state, they exist in an FDA food-safe format.In addition, the frozen liquid contents are preserved at peak levels offlavor and fragrance without the use of conventional preservatives oradditives.

Meanwhile, the dispenser may prepare these foods and beverages in bothhot or cold format by utilizing specific receptacles containing thefrozen liquid content. The integrated system that includes the dispenserand receptacles can safely provide, e.g., coffee, tea, cocoa, sodas,soups, nutraceuticals, vitamin waters, medicines, energy supplements,lattes, cappuccinos, chai lattes, to name a few. While dispensing theproduct, the receptacles are rinsed substantially clean, free ofgrounds, leaves, filters powders or crystals by the dispensing system,thereby qualifying them for recycling.

In some examples, the receptacle is configured such that the receptaclecan be perforated before the receptacle is inserted into the apparatus,can be perforated after the receptacle is inserted into the apparatus,or both. The receptacle may include an unfilled region, e.g., headspacebetween the frozen liquid content and the closure, wherein the region isconfigured to include an inert or reduced reactivity gas in place ofatmospheric air in the receptacle. This region also allows movement ofthe frozen liquid contents within the receptacle to allow for creationof a flow path for diluting/melting fluids around the frozen liquidcontents during product preparation.

The disclosed subject matter includes a process for producing a liquidfood or beverage from a package containing frozen liquid contents. Theprocess includes providing frozen liquid contents in a sealed container,wherein the container is configured to store the frozen liquid contents.In this embodiment, the process always includes melting the frozenliquid contents in the sealed container to generate a melted liquid. Theprocess includes perforating the sealed container at a first location topermit dispensing of the melted liquid from the container to create aconsumable liquid food or beverage.

In some examples, melting the frozen liquid contents includesperforating the sealed container at a second location to permitinjection of a heated liquid or heat in another format into thecontainer to melt and dilute the frozen liquid contents in the sealedcontainer. Melting the frozen liquid contents can include applying heator electric frequency energy externally to the sealed container orwithin the sealed container via an injected liquid, gas, or steam tomelt the frozen liquid contents into a consumable liquid form.

In addition to the food and beverage packaging system, the systems andtechniques described herein include an apparatus for melting and/ordiluting frozen liquid contents stored within this packaging system,wherein the frozen liquid contents of the package are made from food andbeverage concentrates, extracts and other consumable fluid types with orwithout nutrients, and various methods for delivering these meltedand/or diluted contents for immediate consumption. The techniquesdescribed herein allow, for example, consumers to conveniently andspontaneously create a single-serve, or multi serve consumable beverageor liquid-based food directly from a receptacle such that the producthas the desired fresh taste, potency, volume, temperature, textureand/or the like. To achieve this goal, frozen liquid contents andpreferably flash-frozen liquid contents, made from concentrates,extracts, and other consumable fluid types can be packaged in a gasimpermeable, MAP packaged, full barrier and residue-free filterlessrecyclable receptacle. Further, this receptacle is designed to beaccommodated and used by a machine-based dispensing system to facilitatethe melting and/or diluting of the contents and deliver a product withdesired characteristics, including taste, aroma strength, volume,temperature, color and texture, so that consumers can consistently andconveniently experience a level of superb taste and freshness that isunavailable by any other means in use today. Unlike current single-servecoffee makers, which create a finished product via a brewing process(e.g., the extraction of soluble products from solid coffee grounds),the disclosed approach creates a product by melting and diluting afrozen extract or concentrate created through an earlier manufacturingprocess, which can take place in a factory environment under idealconditions to capture and preserve flavor.

In one aspect of the invention, a dispenser for producing a food orbeverage liquid product from a frozen contents in a receptacle includesa chamber configured to hold the receptacle and a non-diluting heaterconfigured to heat at least one of the receptacle when held in thechamber and the frozen contents within the receptacle when held in thechamber. The non-diluting heater does not add liquid to an interior ofthe receptacle when held in the chamber. The dispesner also includes areservoir configured to contain a liquid in which the reservoir includesa reservoir outlet configured to withdraw liquid from the reservoir. Thedispenser further includes a product outlet configured to withdraw afood or beverage liquid product from the receptacle when held in thechamber and a controller and a computer readable memory comprisinginstructions that when executed by the controller cause the dispenser toselectively perform at least one of: heating at least one of thereceptacle and the frozen contents within the receptacle using thenon-diluting heater and withdrawing liquid from the reservoir throughthe reservoir outlet.

In another aspect of the invention, a method of producing a melted foodor beverage liquid product from a receptacle containing frozen liquidcontents includes receiving a receptacle in a chamber of a dispenser.The receptacle defines an enclosed inner volume containing a frozenliquid contents. The method also includes identifying a characteristicof at least one of the receptacle and the frozen liquid contents andmelting at least a portion of the frozen liquid contents to generate amelted food or beverage liquid product by selectively performing atleast one of: heating at least one of the receptacle when held in thechamber and the frozen liquid contents within the receptacle when heldin the chamber without adding liquid to an interior of the receptaclewhen held in the chamber, supplying a dilution liquid to the interior ofthe receptacle, and applying motion to at least one of the receptacleand the frozen liquid contents. The selectively performing at least oneof heating, supplying a dilution liquid, and applying motion is based onthe identified characteristic. The method further includes perforatingthe receptacle and dispensing the melted food or beverage liquid productfrom the receptacle.

In a further aspect of the invention, a method of producing a meltedfood or beverage liquid product from a receptacle containing frozenliquid contents includes receiving a receptacle in a dispenser. Thereceptacle defines an enclosed inner volume containing a frozen liquidcontents. The method also includes identifying a characteristic of atleast one of the receptacle and the frozen liquid contents and removingthe frozen liquid contents from the receptacle into a chamber. Themethod further includes melting at least a portion of the frozen liquidcontents to generate a melted food or beverage liquid product byselectively performing at least one of: heating the frozen contentswithout combining a liquid with the frozen liquid contents, combining adilution liquid with the frozen liquid contents, and applying motion tothe frozen liquid contents. The selectively performing at least one ofheating, combining a dilution liquid, and applying motion is based onthe identified characteristic. The method still further includesdispensing the melted food or beverage liquid product.

In yet another aspect of the invention, a dispenser for producing a foodor beverage liquid product from a frozen contents in a receptacleincludes a chamber configured to hold a receptacle defining an enclosedinner volume containing a frozen liquid contents and a dilution liquidinlet configured to supply a dilution liquid to the inner volume of thereceptacle when held in the chamber. The dispenser also includes aperforator configured to perforate the receptacle and form a productoutlet from the receptacle for a food or beverage liquid product and anagitator configured to impart motion to at least one of the receptacleand the frozen liquid contents in the receptacle that increases a flowpath from the dilution liquid inlet to the product outlet taken by atleast a portion of dilution liquid, when supplied, relative to a flowpath from the dilution liquid inlet to the product outlet taken by theportion of dilution liquid without the imparted motion.

In an aspect of the invention, a dispenser for producing a food orbeverage liquid product from a frozen contents in a receptacle includesa chamber configured to hold a receptacle defining an enclosed innervolume containing a frozen liquid contents and a perforator configuredto perforate the receptacle and remove at least a portion of the frozenliquid contents from the receptacle into a melting vessel. The dispenseralso includes an agitator configured to impart motion to at least one ofthe melting vessel and the frozen liquid contents in the melting vesseland a non-diluting heater configured to heat at least one of the meltingvessel and the frozen contents within the melting vessel. Thenon-diluting heater does not add liquid to an interior of the receptaclewhen held in the chamber. The dispenser further includes a productoutlet configured to dispense the food or beverage liquid product.

Accordingly, there has thus been outlined, in broad terms, features ofthe disclosed subject matter in order that the detailed descriptionthereof that follows may be better understood, and in order that thepresent contribution to the art made by the apparatus and techniquesdisclosed herein may be better appreciated. There are, of course,additional features of the disclosed apparatus and techniques that willbe described hereinafter. It is to be understood that the phraseologyand terminology employed herein are for the purpose of description andshould not be regarded as limiting. Moreover, any of the above aspectsand embodiments can be combined with any of the other aspects andembodiments and remain within the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Various objects, features, and advantages of the disclosed techniquescan be more fully appreciated with reference to the following detaileddescription of the disclosed subject matter when considered inconnection with the following drawings, in which like reference numeralsidentify like elements.

FIGS. 1A-1G illustrate various embodiments of receptacle geometries andfrozen liquid contents configured in different forms and packaged toallow a desired flow of a liquid through the frozen liquid contents,according to some embodiments.

FIGS. 2A-2D illustrate various embodiments showing how the dilutionsystem may add or deliver a liquid to/from the frozen liquid contents bypiercing the packaging and externally and controllably heating thepackaging so melting and dilution is a result, according to someembodiments.

FIG. 3 illustrates a method of melting the frozen liquid contentswithout the use of a melting/diluting liquid, but rather with somealternative source of heat, according to some embodiments.

FIGS. 4A-4D illustrate an exemplary machine-based apparatus that canaccommodate a variety of receptacles geometries, according to someembodiments.

FIG. 5 illustrates a range of exemplary packaging options and receptacleshapes that could be accommodated by a machine-based apparatus,according to some embodiments.

FIGS. 6 and 7 illustrate two versions of receptacles with identical endgeometries and height, but different sidewall profiles, according tosome embodiments.

FIGS. 8 and 9 illustrate two versions of a sidewall indentation in areceptacle, a feature that may be used both for expediting liquefactionand for product identification, according to some embodiments.

FIGS. 10A-10E illustrate five possible needle geometries that may beused to perforate a receptacle, according to some embodiments.

FIG. 11 illustrates the use of centrifugal motion to expedite liquefyinga frozen liquid content, according to some embodiments.

FIGS. 12A and 12B illustrate a spring-loaded needle, according to someembodiments.

FIGS. 13A-13D illustrate a process for producing a food or beverage froma frozen liquid content, according to some embodiments.

FIG. 14A illustrates a side cross-sectional view of a receptacle with aninner platform, according to some embodiments.

FIG. 14B illustrates a side cross-sectional view of a receptacle with aninner platform and a dislodged frozen liquid contents, according to someembodiments.

FIG. 14C illustrates a liquid frozen contents platform, according tosome embodiments.

FIG. 14D illustrates a liquid frozen contents platform with an overflowtube, according to some embodiments.

FIG. 15A illustrates a side cross-sectional view of a receptacle,according to some embodiments.

FIG. 15B illustrates a side cross-sectional view of a detail A of FIG.15A, according to some embodiments.

FIG. 16 illustrates a side cross-sectional view of a receptacle with aplatform having an overflow tube, according to some embodiments.

FIG. 17 illustrates a side cross-sectional view of a receptacle with aplatform having an overflow tube, according to some embodiments.

FIG. 18 illustrates a side cross-sectional view of a receptacle with anannular platform designed and sized to fit over a raised protrusion onthe end layer of the receptacle, according to some embodiments.

FIG. 19 illustrates a side cross-sectional view of a receptacle with adomed end layer, according to some embodiments.

FIGS. 20A and 20B illustrate an operation of a receptacle with a domedend layer, according to some embodiments.

FIG. 21 illustrates a side cross-sectional view of a receptacle with aflat end layer and with partially melted frozen contents, according tosome embodiments.

FIGS. 22A-D illustrate various features for increasing the rigidity of aplatform for holding frozen contents, according to some embodiments.

FIG. 23 illustrates a platform with mixing tabs protruding from thesurface of the platform, according to some embodiments.

FIG. 24 illustrates an underside view of a frozen content mixingplatform preparing to engage a perforator, according to someembodiments.

FIG. 25 illustrates engagement between a perforator and a frozen contentmixing platform, according to some embodiments.

FIG. 26 illustrates a perforator outside of a receptacle preparing toengage a frozen content lifting platform within the receptacle,according to some embodiments.

FIG. 27 illustrates engagement between a perforator and a frozen contentmixing platform, according to some embodiments.

FIG. 28 illustrates partial melting of a frozen content disposed on afrozen content mixing platform, according to some embodiments.

FIGS. 29A and 29B illustrate perforator internal and external channelspermitting liquid flow, according to some embodiments.

FIGS. 30A-D illustrate various perforators having channels or shapes topermit liquid flow through or past the perforator, according to someembodiments.

FIG. 31 illustrates a side cross-sectional view of a receptacle with araised lip, according to some embodiments.

FIG. 32 illustrates a side cross-sectional view of a receptacle,according to some embodiments.

FIG. 33 illustrates a side cross-sectional view of a receptacle,according to some embodiments.

FIG. 34 illustrates a side cross-sectional view of a receptacle,according to some embodiments.

FIG. 35A-B illustrate portions of a dispenser system, according to someembodiments.

FIG. 36A-B illustrate portions of a dispenser system, according to someembodiments.

FIG. 37A-E illustrate portions of a dispenser system, according to someembodiments.

FIG. 38A-E illustrate portions of a dispenser system, according to someembodiments.

FIG. 39A-B illustrate portions of a dispenser system, according to someembodiments.

FIG. 40 is a cross-section view of a system for heating frozen liquidcontents of a receptacle using radio frequency dielectric heatingaccording to an embodiment of the invention.

FIG. 41 is an isometric view of a cavity cover including two fluiddelivery needles and a central electrode for ohmic heating according toan embodiment of the invention.

FIG. 42 is a cross-section view of a first implementation of the ohmicheating system of FIG. 41 according to an embodiment of the invention.

FIG. 43 is a cross-section view of a second implementation of the ohmicheating system of FIG. 41 according to an embodiment of the invention.

FIG. 44 is an isometric view of a cavity cover including two fluiddelivery needles and two electrodes for ohmic heating according to anembodiment of the invention.

FIG. 45 is a cross-section view of the ohmic heating system of FIG. 44according to an embodiment of the invention.

FIG. 46 is an isometric view, with a rotating cavity bottom shown open,for a heating system using microwave energy to heat frozen liquidcontents according to an embodiment of the invention.

FIG. 47 is an isometric view of the rotating cavity bottom of FIG. 46 ,shown closed, according to an embodiment of the invention.

FIG. 48 is a cross-section view of the heating system of FIG. 46according to an embodiment of the invention.

FIG. 49 is a graph depicting the dielectric loss factor of water andice.

FIG. 50 is an isometric view of an infrared heating system according toan embodiment of the invention.

FIG. 51 is an isometric view of two spiral coiled electrodes accordingto an embodiment of the invention.

FIG. 52 is a second isometric view of the two spiral coiled electrodesof FIG. 52 .

FIG. 53 is an isometric view of two rectangular electrodes according toan embodiment of the invention.

FIG. 54 illustrates portions of a dispenser system, according to someembodiments.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forthregarding the systems and methods of the disclosed subject matter andthe environment in which such systems and methods may operate in orderto provide a thorough understanding of the disclosed subject matter. Itwill be apparent to one skilled in the art, however, that the disclosedsubject matter may be practiced without such specific details, and thatcertain features, which are well known in the art, are not described indetail in order to avoid complication of the disclosed subject matter.In addition, it will be understood that the embodiments described beloware exemplary, and that it is contemplated that there are other systemsand methods that are within the scope of the disclosed subject matter.

The various techniques described herein provide for the packaging of oneor more frozen foods or beverage liquids, using a filterless receptacle,and how to efficiently convert this frozen liquid contents into a highquality, tasty food or beverage product. The single chamber filterlessreceptacle can be designed such that a machine-based system mayaccommodate the receptacle and facilitate the melting and/or diluting ofthe frozen liquid contents to conveniently produce a consumable liquidbeverage or food product directly therefrom with a desired flavor,potency, volume, temperature, and texture in a timely manner without theneed of brewing. For simplicity, a frozen food or beverage liquid may bereferred to as the “frozen liquid contents” or “frozen liquid content”.

In some embodiments, the liquid that is frozen to create the frozenliquid content may be any frozen liquid matter, which in someembodiments can be derived from a so-called extract, e.g., a productobtained through the removal of certain dissolvable solids using asolvent. For example, the extract may be created using water to removecertain desirable dissolvable solids from coffee grounds or tea leaves.Somewhat confusingly, certain liquid extracts with a high-solids contentare often referred to as a concentrated extract. The use of the term“concentrated” in this context may or may not be entirely accuratedepending on whether the high solids content was achieved purely throughsolvent extraction of the solids or through a secondary step ofconcentration wherein solvent was removed from the liquid by some means,for example, by reverse osmosis or evaporation using heat orrefrigeration, to increase its potency or strength.

In contrast to a “brewer”, which is a system for creating beverageproducts through extracting or dissolving solids (e.g., separately at afactory where the grinds/leaves etc. may be processed in bulk), theapparatus described herein to facilitate beverage creation is not abrewer. Rather, it melts and/or dilutes with dispensing functions thatmay be used to create a beverage from a previously brewed frozen liquidcontent.

The liquid used to make the frozen liquid content may also be a pureconcentrate, e.g., a product obtained only by removing water or anothersolvent from a consumable compound such as a fruit juice or a soup, tocreate a fruit juice concentrate or a broth concentrate. In someembodiments, water may be removed from milk to create condensed milk.High TDS values and/or concentrations may be desirable either to reducetransportation costs and shelf space, or for convenience, for potencyand serving size versatility of created products via dilution, or forenhanced shelf life due, for example, to enhanced anti-microbialactivity due to reduced water activity. These specifics are intended toexemplify variation, but any liquid food or beverage product, regardlessof how it is created, and regardless of its solids content falls withinthe scope of the present disclosure.

In some embodiments, the frozen liquid content can be one of a coffee ortea extract, lemonade, a fruit juice, a broth, a liquid dairy, analcohol, a syrup, a viscous liquid, or any liquid food product that isfrozen. Frozen liquid content can be matter created with or withoutnutritive value, may be flavored naturally or artificially, and bepackaged with or without a preservative, and/or the like. The frozenliquid contents may compose carbohydrates, proteins, dietary mineralsand other nutrients that support energy or metabolism. The frozen liquidcontents may include or be enhanced with additives such as vitamins,calcium, potassium, sodium, and/or iron, among others. The frozen liquidcontents may include preservatives such as antimicrobial additives,antioxidants and synthetic and/or non-synthetic compounds. Examples ofpreservative additives may include lactic acid, nitrates and nitrides,benzoic acid, sodium benzoate, hydroxybenzoate, propionic acid, sodiumpropionate, sulfur dioxide and sulfites, sorbic acid and sodium sorbate,ascorbic acid sodium, tocopherols, ascorbate, butylated hydroxytoluene,butylated hydroxyanisole, gallic acid and sodium gallate, an oxygenscavenger, disodium EDTA, citric acid (and citrates), tartaric acid, andlecithin, ascorbic acids, phenolase, rosemary extract, hops, salt,sugar, vinegar, alcohol, diatomaceous earth and sodium benzoate, amongothers. It will be understood that this listing of additives is intendedto be within the scope of the techniques described herein, and thespecifically referenced additives are exemplary only, and can alsoinclude derivatives thereof as well as other chemical compounds.

The frozen liquid contents or matter may or may not have suspendedsolids, and may include non-dissolvable solids. In some embodiments, theconcentrate, extract, or other consumable fluid form which the frozenliquid contents are made may include additives that completely dissolvein a solvent before freezing. In some embodiments, the frozen liquidcontents may also include a mass of a composition that is not dissolvedwithin the frozen liquid contents during the packaging process, but isdissolved by the machine-based system during the creation of a beverageor food product with desired characteristics.

FIGS. 1A-1E show various embodiments of how the frozen liquid contentsmay be structured and packaged to allow for a desired flow of apressurized or gravity fed diluting liquid by a machine-based systemthrough the receptacle holding the frozen liquid contents. In additionto facilitating heat transfer to the frozen liquid contents, thediluting liquid may be effective at creating turbulent motion to therebyexpedite melting in a variety of ways that are not outside the scope ofthe techniques described herein. Within the receptacle, the frozenliquid contents may be frozen into any useful shape or size.

In FIG. 1A, a section view of receptacle 110 is shown (without a sealinglid in place), wherein the receptacle defines a cavity for packaging ofthe frozen liquid contents 120. The frozen liquid contents 120 can befrozen in-place by filling the receptacle with a liquid and thenfreezing the liquid, or the frozen contents can be frozen into aparticular shape and then placed in the receptacle. In this instance,the frozen liquid contents are shown displaced away from the bottomportion of the receptacle to allow clearance for an exit needleperforation and to create a pathway around the outer surface of thefrozen liquid contents in the receptacle for creating a desired flow ofa melting/diluting liquid through the receptacle and around the frozenliquid contents to produce a beverage of a desired flavor, strength,volume, texture and temperature. FIG. 1B illustrates another embodiment,wherein the frozen liquid contents have been molded to a shapeconfigured to match the outside of the receptacle and subsequentlyloaded, such that the pre-molded shape defines a through-hole 130 in itsbody and a relief portion 132 below for accommodating an exit needleperforation to provide for a desired liquid flow there through withoutblockage or back pressure. FIG. 1C shows a plurality of frozen liquidcontent pieces 140-180 provided in multiple and various shapes andsizes, with large interstitial spaces to provide for a desired liquidflow though the receptacle and around the frozen liquid contents. Insome embodiments the frozen liquid contents within the sealed receptaclemay include a plurality of concentrates and compositions. For example,frozen liquid contents 140 and 150 could comprise a lemonadeconcentrate, while frozen beverage concentrates 160, 170, and 180 maycomprise a tea concentrate, resulting in an “Arnold Palmer”.

FIGS. 1D and 1E illustrate an embodiment for an alternatively shapedreceptacle 115 that includes a bottom portion having a dome 195(bistable or otherwise). In FIG. 1D the receptacle 115 is shown in itsinitial condition when the frozen liquid contents are added and frozenin place, complete with a frozen dome structure 195 in the bottom, withthe dome structure in a primary or initial position, distended outwardlyfrom the receptacle. FIG. 1E shows the condition of the receptacle 115after the dome 195 has been displaced to a secondary position directedinward into the cavity of the receptacle such that the liquid frozenliquid contents 190 are displaced upwardly, into the headspace,reverting or “exchanging” the space or void between the inside bottom ofthe receptacle and the bottom portion of the frozen liquid contents.This displacement desirably creates a space for an exit perforationneedle in the bottom of the receptacle and also creates flow paths forany melting/dilution liquid to pass around the outside of the frozenliquid contents.

FIG. 1F illustrates a receptacle 196 comprising a multi-faceted shape.In this embodiment, the receptacle 196 includes different shape portions196A-E. In some embodiments, the process of filling, melting anddiluting a frozen liquid content may be generally unaffected by the sizeor shape of the receptacle. In some embodiments, certain designconsiderations can be taken into account with regard to using geometriesthat may, for example, promote and facilitate unrestricted release ofthe frozen liquid contents, accommodate needle perforation, enable thedevelopment of clearance around the frozen liquid contents to promote aready flow path for diluting liquids, and/or the like. For example, oneor more of such design considerations can be met with positive(non-locking) draft in the sidewalls of the receptacle where it is incontact with the frozen liquid contents. Draft can be achieved by, forexample, tapering the sidewalls of the receptacle, such as tapering thesidewalls outward from bottom of the receptacle to top of the receptacle(e.g., the diameter of the receptacle gets larger nearer the top of thereceptacle). This can create a positive draft such that pushing thefrozen liquid contents away from the bottom of the receptacle createsclearance around the sides of the frozen liquid contents (e.g., whichavoids mechanical locking of the frozen liquid contents against thesides of the receptacle). Such positive draft can be used to create anatural flow path for diluting liquids to travel through the receptacle,such as liquids flowing from an entry needle to an exit needle thatperforate the receptacle.

FIG. 1G illustrates a receptacle 197 with a lid 198 that includes a pulltab 199 that may be removed by the consumer. The pull tab 199 can beremoved to facilitate use of a straw or similar device in combinationwith the receptacle 197. As another example, the pull tab 199 can beremoved to facilitate introduction of diluting fluids into thereceptacle 197.

FIG. 2A illustrates a perspective view of the receptacle, including aformed seal closure such as a lid structure 118, which may include apuncture 210 therein, whereby, in some embodiments, a dilution fluid,which may also act as a melting agent, can be introduced into thereceptacle. The lid structure 118 can include a tab 119 for allowingmanual removal of the lid to access the frozen liquid contents without aneed for perforation of the lid in certain instances. This lid structurecan be made from the same material as the receptacle to better supportefforts toward single-stream recycling. The lid structure can be made ofsufficient gage thickness to adequately withstand internal pressurecreated by, for example, the melting/diluting liquid, which may increaseand decrease with forces created by the accommodating system. Forexample, a vibratory, centrifugal, or rotation platform or the like thatfacilitates melting, or the flow rate of a diluting liquid injected willaffect the pressure put on the lid, seal, and receptacle. Furthermore,the perforations made by the accommodating system may impact thepressures created on the hermetic seal, lid, and receptacle. The lid maybe attached to the receptacle by any suitable technique such as, forexample, heat sealing or crimping, radial folding, sonic welding, andthe function can be achieved by any mechanism or form of the lid thatseals the internal cavity and acts as a barrier against gas or moisturemigration.

FIG. 2B shows an alternative embodiment of a punctured lid including twoperforations 215. FIG. 2C illustrates a bottom puncture 220 to allow thedilution liquid to exit the sealed receptacle. These examples are meantto be illustrative, however, as the puncture, or punctures, may be madeanywhere on the receptacle. The punctures may be made in a specificlocation to dispense a solvent, diluting agent, liquid, such as water,gas or steam for a desired melting and dilution environment, andultimately the creation of a desired beverage in a timely manner. Thepunctures may be of any size as needed, for example, to allow oversizesolids (frozen or non-dissolvable solids) to be dispensed from thereceptacle. In some variations, the perforation may be made to allowfrozen structures of a specific size to escape and to be distributedfrom the receptacle to create a fluid, iced, slush, or smoothie-likebeverage. In addition, multiple punctures may be advantageous inproviding venting of the receptacle when melting/diluting fluid is inputtherein.

FIG. 2D illustrates an embodiment having four punctures (230-233)situated in proximity to the periphery of a receptacle 270 for entry ofa liquid through the lid 250 of a receptacle 260 that is loaded top-downinto a machine-based system. As shown in this embodiment, a puncture 240may be provided near the center of the receptacle lid for allowing themelted and diluted frozen liquid contents to exit the receptacle. Inthis figure, the frozen liquid contents (not shown) are frozen withinthe domed bottom of the upside down receptacle to allow for a desiredflow environment, wherein the liquid is redirected by the tapered sidesof the receptacle to the exit perforation. The melted and dilutedliquid, in this example, may flow out of the receptacle into a secondaryreceptacle for consumption from a single or plurality of nozzlesprovided by an accommodating apparatus.

In some embodiments, the frozen liquid contents contained in thesereceptacles can be better preserved when deaerated, or deoxygenated,including use of deaerated or deoxygenated solvents (e.g., water) duringan extraction process when appropriate. In some embodiments, the liquidused to make the frozen liquid contents may be frozen at a time of peakquality in terms of freshness, flavor, taste and nutrition. In someembodiments, such as for a coffee-based beverage, the frozen liquidcontent is flash-frozen during the period of peak flavor immediatelyfollowing extraction to preserve the optimum taste, aroma and overallquality and thereafter distributed in a frozen state for preservingtaste and aroma thereof. For example, an espresso concentrate may bepreserved and may taste best when it is ground within 0-36 hoursfollowing roasting, brewed immediately after grinding, and usingdeoxygenated water during the brewing process. By flash freezing theliquid concentrate, extract, or other consumable fluid during thisperiod of peak flavor immediately following brewing, it is possible tocapture the peak flavor, optimum taste, aroma and overall quality of theextract. Further, by packaging this flash frozen liquid in a gasimpermeable and recyclable receptacle using MAP techniques (as describedfurther herein), and providing the frozen liquid contents are maintainedin a frozen state during subsequent storage and delivery to the finalconsumer, the fresh flavor can be maintained almost indefinitely. Insome embodiments, the frozen liquid content may be frozen by removingheat from a selected and controlled portion of the receptacle so as tolater facilitate dislodging the bonds (adhesion) created between thefrozen liquid content and the sides of the receptacle. For example, incertain embodiments, a liquid content is placed in a receptacle, andheat is removed so as to cause the liquid to freeze starting at the topsurface of the liquid and then to freeze downward. Doing so reduces theadhesion between the frozen liquid content and the interior of thesidewalls of the receptacle.

In some embodiments the packaging may be distributed above freezing ifthe quality of the content can be maintained by some other FDA food safemethod e.g., a syrup used to make carbonated beverages. In someembodiments, the frozen liquid contents may be frozen and never melted,melted once or numerous times during distribution. Distributing andmaintaining the receptacles at a temperature below the freezing point ofthe frozen liquid contents may increase aspects of quality preservationand nutrient-rich food safety, but is not required for all embodiments.In some embodiments, the beverage concentrate is flash-frozen and keptfrozen in its receptacle until it is ready to be melted and/or dilutedimmediately prior to being prepared for consumption.

In some embodiments the frozen liquid content can also be packaged as aplurality of frozen liquid contents, configured in a layered and/orblended format. In some embodiments, the frozen liquid contents can beconfigured in any shape or multiple geometric shapes so long as thecontents will fit within the cavity volume of the receptacle whilemaintaining an unfilled region and are capable of being repositioned forcertain puncture implementations by an accommodating system. In someembodiments, the frozen liquid contents may be crushed or macerated toincrease the surface area of the frozen liquid contents to increasemelting rates.

In some embodiments the liquid comprising the frozen liquid content maybe frozen after it has been measured into the receptacle. In someembodiments the fluid used to create the frozen liquid content may befrozen prior to delivery to the receptacle, e.g., pre-frozen in a mold,extruded, frozen and cut to size, or by other means and then depositedin the receptacle as a frozen solid of some desirable shape. This may bedone in cooperation with the dimensions of a receptacle with a taperedportion such that the frozen liquid content does not interfere withareas of the receptacle designated for puncture. For example, the frozenliquid content can be shaped so as to be displaced away from a puncturearea because its diameter is larger than that of a top, bottom, or otherfirst or second end of a receptacle, as shown in FIG. 1A. Stated anotherway, the frozen liquid contents may be created in a first phase orseparate step, and then received, inserted and sealed in a receptaclethat can be accommodated by a machine-based dispensing system. In someembodiments the liquid beverage concentrate is received as a slurry orliquid, to be frozen, and sealed in the receptacle in turn, or inunison. In some embodiments the frozen liquid contents are of a potency,shape and size, and are structured within a receptacle such that amachine-based system can easily melt and/or dilute the liquid frozenliquid contents, converting the contents to a consumable liquid of adesired flavor, potency, volume, temperature, and texture.

In some embodiments the receptacle for holding/storing the frozen liquidcontents using the techniques described herein includes a cup-shapedportion having a continuous and closed bottom portion, a continuoussidewall extending from the bottom portion, and a sealable top openingdefined by a continuous sidewall that tapers outwardly as it extendsaway from the bottom portion. The wall is uninterrupted by filters orother internal features that would interfere with certain puncture,frozen liquid content displacement and flow implementations.

In some embodiments, the receptacle includes a cavity for storing thefrozen liquid content. The packaging in which the frozen liquid contentsare sealed, before and hereinafter referred to as a “receptacle” couldotherwise be described as a cartridge, a cup, a package, a pouch, a pod,a container, a capsule or the like. The receptacle can be in any shape,styling, color or composition, and may be styled to enhance theliquefaction environment in cooperation with the dispensing apparatus.The packaging may be flexible, have a definitive shape, or combinationthereof. For aesthetic or functional reasons, for example, to complementpod detection or motion drive functions applied to the pod, the walls ofthe receptacle may be concave and/or convex to provide for different podsizes while keeping certain interfacing dimensions constant. Likewise,the color and/or shape can be used to convey information to thedispenser.

For example, FIGS. 6 and 7 illustrate two versions of receptacles 610and 710 with identical end geometries and height, but different sidewallprofiles. The differently curved sidewalls produce different internalvolumes available for the frozen liquid contents and headspace, but thediameter of their two ends and their overall heights are the same.

In some embodiments the receptacle's outer surface is colored or coatedwith a material designed to enhance absorption of infrared energy thatmay be used to heat and/or melt the frozen liquid contents. In someembodiments the shape of the receptacle's sidewall, when seen in sectionview from a first or second end, would be the shape of a star or othernon-circular shape, e.g., one whose perimeter surface area would be muchgreater than that of a smooth cylinder or cone and thereby promoteheating and melting of the frozen concentrate proportionally faster.This may effectively facilitate melting in many ways, includingincreasing that surface area for heat to be transferred to the frozenliquid content through the receptacle, creating a more turbulentenvironment in the receptacle that expedites melting, or directingliquid away from the exit perforation(s) to promote greater heattransfer efficiency within the receptacle.

In some embodiments, as shown in FIGS. 8 and 9 , there is a “keyingfeature” 620 or 621, which can help to promote internal turbulenceduring melting and dilution of the frozen liquid contents and can alsobe of use in identifying the contents or family of products used to fillthe receptacle.

In some embodiments, the receptacle includes a closure for sealing thereceptacle to assist in maintaining a MAP gas environment. In this case,a hermetic seal formed between a lid and the receptacle may beaccomplished using a variety of methods, including, but not limited to apatch, glue, cork, heat seal, crimp, and/or the like. In someembodiments, the closure may be designed to be manually removable, e.g.,with a pull tab on a lid as previously noted, so that the frozen liquidcontent can be used in other ways if a machine-based system forpreparing a consumable beverage is not available. In some embodiments,the apparatus may require a manual perforation instead of a machineimplemented perforation before loading the receptacle into themachine-based dispensing system.

The frozen liquid contents may be packaged in a material that providescontrol of gas migration, e.g., the receptacle may be comprised of a gasimpermeable material for creating a long lasting storage package forpreserving freshness and aroma of the packaged frozen liquid contents.For example, the receptacle may be comprised of an aluminum substrate orother metal material and typically prepared with a coating approved bythe FDA for contact with food, if needed. As another example (e.g., ifrecyclability is not a critical concern), the receptacle may becomprised of a multi-layer barrier film including, for example, a layerof EVOH plastic. In some embodiments, if the receptacle is fabricatedfrom a metal, the receptacle will preferably be made from a highlythermally conductive material such as aluminum and thereby be supportiveof faster heat transfer, especially if a heated dilution liquid is notthe primary means for melting the frozen liquid contents. In someembodiments the packaging may include edible packaging materials thatmay be dissolved and consumed. In some embodiments the receptacle andits closure are comprised of a gas impermeable, recyclable material suchthat a spent receptacle, including the closure and other packagingfeatures, can be recycled in its entirety

In some embodiments, the frozen liquid contents is packaged withheadspace, with no headspace or limited headspace. As mentioned above,headspace refers to any excess atmosphere within a sealed receptacle,which, optionally, is located between a top portion of the frozen liquidcontents and the lid or closure portion of the receptacle. Furthermore,any headspace in the packaging receptacle may be advantageously filledusing a MAP gas, such as argon, carbon dioxide, nitrogen, or anothergaseous compound which is known to be less chemically active than air oroxygen. In some embodiments the top or outermost layer or envelope ofthe frozen liquid contents may be layered with a frozen, deaeratedcoating of water which may act as a preservative barrier. In someembodiments the frozen liquid contents are vacuum sealed in a flexiblereceptacle. In some embodiments the frozen liquid contents are packagedin a receptacle in a manner that minimizes the surface area contact ofcontents with the atmosphere, especially oxygen gas, but also any gasthat carries off aroma.

In some embodiments the receptacle is coated on the inside with amaterial that significantly reduces the force needed to dislodge thefrozen liquid contents from the sides or bottom of the receptacle tofacilitate movement of the frozen liquid contents out of the way or bythe action of a perforating needle and to create unrestricted pathwaysfor melting and/or diluting liquids to pass around the exterior surfaceof the frozen liquid contents en route to the exit perforation. In someembodiments the bottom of the receptacle incorporates a dome structure(bistable or otherwise) which can be distended downward, away from thebottom of the receptacle during filling and freezing of the liquidcontents and subsequently inverted upward to a its second stableposition after freezing to hold the frozen liquid contents away from thebottom of the receptacle to facilitate needle penetration and/or flow ofdiluting liquids around the exterior surface of the frozen liquidcontents en route to the exit perforation. In some embodiments the domeis inverted at the factory prior to shipment of the product toconsumers. In some embodiments the dome is inverted by the consumerimmediately prior to use or by the machine as a part of insertion andneedle penetration. In some embodiments the dome is inverted by themachine. These embodiments are merely examples and not cited to limitthe functions or features of the receptacle that may facilitatedislodging frozen liquid contents or beverage creation. Moreover, in theexample above, the frozen liquid content is displaced upward into aheadspace by the perforating needle or dome. However, in otherembodiments, the frozen liquid content can be displaced in a differentdirection (e.g., downward or sideways) into an unfilled region of thereceptacle and remain within the scope of the invention. Similarly, thefrozen liquid content can be of a shape and size to facilitate fractureby a needle penetrating the bottom or top of the receptacle.

In some embodiments the frozen liquid contents may be packaged andstructured in a receptacle of a specific size and shape that allows thereceptacles to be accommodated by current machine-based dilution systemsor systems on the market that are designed for extracting solutes orbrewing coffee for the facilitation of creating a beverage of a desiredflavor, potency, volume, temperature and texture.

In some embodiments the packaging of the frozen liquid contents includesadditional barriers or secondary packaging that protects the frozenconcentrates from melting or exposure to ultraviolet light duringdistribution. For example, packaging frozen liquid contents in areceptacle that is further packaged within a cardboard box adds a layerof insulation and would thereby slow temperature loss or melting of thefrozen liquid contents, e.g., when such temperature loss or melting isundesirable.

In embodiments of the present techniques, the apparatus for creating afood or beverage from frozen liquid contents advantageously includes areceptacle that is filterless, as distinguishable from the filteredreceptacles currently available, as exemplified, for example, by U.S.Pat. No. 5,325,765, among other filtered beverage receptacles. Afilterless receptacle, and, for example, (1) the (virtually) completeremoval of the frozen liquid contents during melting and/or dilution andsubsequent delivery and (2) the use of a homogeneous material ofconstruction, renders the receptacle ideally suited for recycling.

In some embodiments the receptacle is configured to be accommodated by amachine-based system and capable of receiving a liquid dispensedtherefrom to further facilitate the melting and/or dilution of thefrozen liquid contents into a consumable liquid product with a desiredset of characteristics.

In some embodiments the receptacle may be large enough that it cancontain the melted contents and all of the added dilution liquid fromthe machine-based system and the finished product can be consumedimmediately therefrom. The perforation used to add dilution liquid maybe suitable for subsequent use with a straw or other means to allowconsumption directly from the receptacle, as opposed to dispensing thediluted and/or melted contents into a secondary container.

In some embodiments the receptacles with frozen liquid contents areprovided in a controlled portion arrangement, wherein the controlledportion arrangement can comprise a single-serving sized format, or abatch-serving sized format for producing multiple servings. In someembodiments the machine-based system may accommodate the receptacle, ora plurality thereof, in any method, shape, or form to facilitate themelting and dilution of the frozen liquid contents. In some embodimentsa machine-based system may accommodate multiple receptacle types andsizes for a larger array of product possibilities.

In some embodiments the receptacle may be perforated either by theconsumer or by the machine-based system. For example, the consumer mayremove a patch to expose a perforation built into the receptacle beforeit is received by the machine-based system. Alternatively, themachine-based system may perforate the sealed receptacle using a varietyof methods, including a puncture needle or pressure to rupture thereceptacle.

In some embodiments the packaging may become perforable only afterexposure to higher temperature or mechanical action. For example, thepackaging may be made of a sponge-like material that the frozen liquidcontents can permeate when heated. In an alternative example, the frozenliquid content is thawed or liquefied from the action as to allow amachine-driven needle to penetrate the receptacle and content with lessforce.

As previously stated, the perforation may be a single hole. In someembodiments multiple perforations may be provided in the receptacle atmultiple locations. In general, since there is no need for filtration ofthe melted frozen liquid contents, the perforations described herein areintended for the introduction of a melting/diluting liquid, gas, orsteam or to allow the melted frozen liquid contents to exit thereceptacle. In some embodiments, the receptacle is perforated and apush-rod or the like is introduced to displace the entire frozen liquidcontents out of the receptacle before melting and diluting. In someembodiments the perforations may be staged—one perforation then anotheror multiple perforations staged at different intervals in the dispensingprocess. The machine-based system may displace the frozen liquidcontents, or the consumer may displace the frozen liquid contents,remove it from its packaging, and load only the frozen liquid contentsinto the system. In some embodiments the receptacle is perforated by themachine-based system in a location that allows the entire frozen liquidcontents to exit the receptacle before or after melting so as not towaste any of the beverage product and to remove any recyclingcontaminants from the receptacle. In some embodiments, the frozencontent is squeezed from the receptacle. In other embodiments, aperforator pushes the frozen content from the receptacle. A blade may beused to remove the lid, or alternatively, pressure may cause the lid toburst and remove from the pod.

For embodiments in which all or a part of the frozen liquid contents isdisplaced from the receptacle into a separate chamber (i.e., meltingvessel), all of the various techniques used to prepare the final food orbeverage product relevant to preparation in the receptacle applyequally, and the final product can be dispensed from the vessel. Forexample, the separate chamber can be heated, be agitated (as describedbelow), and receive dilatation liquid in the same manner as set forthfor heating, agitating, and injecting dilution liquid into thereceptacle. For the sake of clarity, implementations of the inventionare described in terms of performing the product preparation actions ona receptacle containing the contents, but it is within the scope of theinvention to conduct these actions on the separate chamber.

The perforation may be made before, after, or during the time when thefrozen liquid contents are melted and/or diluted. In some embodimentsthe frozen liquid contents are melted and exit the receptacle beforebeing diluted by a dispensed diluting agent for an ideal beverage. Insome examples of the present techniques the frozen liquid contents maybe diluted using a dispensed liquid before the contents are distributedinto a subsequent or secondary receptacle. In some embodiments thefrozen liquid contents are melted and diluted simultaneously. Forexample, in some embodiments, a liquid may be introduced into thereceptacle containing frozen liquid contents to melt and/or dilute thefrozen liquid contents simultaneously or in unison.

Although pushing a pressurized liquid around or through the frozenliquid contents within a receptacle can be effective at expeditingmelting rates, other methods exist to achieve the same outcome andenhance the speed of this process. FIG. 3 illustrates a method forproducing a desired beverage that does not use a pressurized liquid tosimultaneously melt and/or dilute the frozen liquid contents. The frozenliquid contents 310 are enclosed in a perforable receptacle. Thereceptacle 320 is perforated and accommodated by a machine-based systemand the frozen liquid contents are liquefied via a melting componentsuch as an external heat source or the like. The process for producing aconsumable liquid product from a frozen liquid content of the techniquesdescribed herein may be carried out by an initial step of providing thecontent in a sealed receptacle for storing therein. The receptacle isaccommodated by a machine-based system that applies heat to thereceptacle via an external heat source for melting the frozen food orbeverage into a consumable liquid food or beverage form, wherein thesealed enclosure is perforated for permitting dispensing of theconsumable liquid beverage directly from the sealed enclosure.

In some embodiments, the negative energy contained in the frozen liquidcontent absorbs excess heat from the diluting liquid, gas or steam usedto make the consumable food or beverage as a method of facilitating acold beverage from a dispenser without need for a refrigeration systemwithin the dispenser. In this embodiment involving beverages intended tobe served cold, melting and dilution of the frozen liquid contents iscarefully managed using a combination of external heat, energy containedwithin an ambient temperature diluting liquid, and the use of relativemotion between the melting/diluting liquid and frozen liquid contents toenhance liquefaction with the goal to minimize the overall temperatureof the finished product.

Further referring to FIG. 3 , the melted beverage content 330 exitingits receptacle is diluted with an additional liquid dispensed via themachine-based system in a secondary step or in unison with a desireddiluting agent. The melted contents may be dispensed undiluted, before,after, or simultaneously with the addition of a distinct liquid fordilution. This may include capturing the melted beverage content in aliquid reservoir that mixes the two liquids before being dispensedtogether by the machine-based system. When distributed, a secondaryreceptacle 340 receives the melted contents and diluting agent whenappropriate.

In some embodiments, a secondary receptacle used to collect themelted/diluted contents may include any receptacle known to hold liquidfood or beverages. This secondary receptacle could be a container,thermos, mug, cup, tumbler, bowl, and/or the like. This secondaryreceptacle may or may not be included in the secondary packaging. Note:an example of this would be a consumer package with a soup bowlcontaining instant rice or noodles sold along with a receptacle offrozen liquid broth concentrate that combines to make a bowl of soupafter the frozen liquid contents are melted and/or diluted anddischarged into the secondary packaging. Alternatively, the secondaryreceptacle may be separately provided by the consumer.

In some embodiments, the consumer may desire a beverage with no dilutionof the frozen liquid contents. e.g., the frozen liquid contents arealready at the correct flavor, volume and potency. For example, thefrozen liquid contents may already be at a desired TDS level forconsumption, e.g., an espresso, or hot fudge sauce and need to only bemelted and dispensed at the desired temperature and texture. Forexample, the machine-based system may melt the frozen liquid contents byputting a thermally conductive receptacle against a coil heater or byirradiating it with infrared light or by impinging a heated gas or steamagainst the outside of the receptacle and then puncturing the receptacleafter the contents reach a desired temperature. Furthermore, the frozenliquid contents may be conveniently dispensed from the machine-basedsystem into a subsequent container. In some examples, the lid is removedprior to or after melting and heating for direct consumption from thereceptacle.

FIGS. 4A through 4D illustrate an exemplary machine-based apparatus thatcan accommodate a variety of different receptacles, according to someembodiments. The system can be, for example, a melting system. Thereceptacles can include, for example, a variety of different filterlessreceptacles, of varying sizes and shapes, each holding some amount offrozen liquid contents. The apparatus can be configured to performmelting, diluting, and delivery functions for the purpose of creating abeverage or food product with desired characteristics, as describedherein.

In FIG. 4A, the system 400 (also called a “dispenser” herein) includes acassette 430 into which receptacles of different sizes and/or shapes canbe loaded. Once loaded with a single receptacle, the cassette 430 can beslid into place, with the receptacle passing through a clearance tunnel435 until it is centered on the main system body 410. Instructions foruse of the melting system 400 can be communicated to a user via adisplay 420. Solvent (e.g., water) to be used for melting/diluting thefrozen liquid contents of the receptacle is stored in the holding tank440 until needed.

Referring to FIGS. 4B and 4C, once the receptacle is properly placed forinteraction with the system, a needle support arm 450 is moved towardthe receptacle using any known means, which, by way of example only,could include a motor 451, including electric or gas-driven variationsand/or a screw 452, until the needle 457 punctures the closure end ofthe receptacle. Use of a manual lever to puncture the receptacle is alsowithin the scope of the invention. The shape of the needle may comprisea protruding tip such that it may be inserted into the receptacle to acertain depth and angle to chip, fracture, or dislodge a portion offrozen liquid content to promote flow paths to an exit point. The needle457 may spin in a screw motion at a certain depth to facilitatepenetration of the receptacle and/or frozen liquid content.Alternatively, the needle may retract after puncture to a second depthwithin the receptacle or from the receptacle completely to ease initialdispensing pressures or provide unobstructed perforation exits. Theneedle may be heated before or during insertion into the receptacle. Aheated probe may be inserted into the receptacle through one of thepuncture to accelerate melting of dispensed contents. Depending on thereceptacle design and its contents, a second needle support arm 455 canbe moved toward the receptacle to penetrate the bottom of the receptacleusing a similar motor 454 and drive screw 455. A heater, such as a plateheater or an IR heating source (not shown) may be used to preheat ormelt the frozen liquid contents depending on the selected product andprocess desired. When needed, a melting/diluting liquid stored in aholding tank 440 can be passed through a heat exchanger (not shown),using tubing (not shown), to pass through needle 457 and into the nowpunctured receptacle. Thereafter the melted liquid can exit from thereceptacle through needle 456. In one embodiment, the perforation needle457 may inject a hot liquid, steam, gas, or any combination thereofdirectly into the pod as a way to aerate the liquefied product forcreating, in a specific example, a froth-like texture for a coffee-baseddairy product like cappuccinos and lattes. In one embodiment, a needleinjected into the pod may include no exiting structure and be usedpurely to stabilize a pod.

In further embodiments, the cavity of a dispenser for receivingreceptacles of different sizes may alternatively have perforators thatcan be retractable based on the shape of the receptacle being received.The perforator, which may be a needle, guillotine, blade, crusher or thelike, may be retractable utilizing any known mechanical means, e.g., apivot to rotate the perforator away from the receptacle to avoidpiercing the receptacle, a telescoping mechanism to slide the perforatoraway from obstructing an inserted receptacle, a screw mechanism drivenby a stepper motor or the like to raise or lower the perforator asneeded, a spring driven device, a flexible tube that is “dispensed” froma roll or coil and retracted back to this location after use, or otheralternative. In some embodiments, the perforators may be moved by amotor or solenoid. In some embodiments the perforator may be movedlinearly while in other embodiments the perforator may be moved throughsome more complex path, for example, in a circular path around theperiphery of the opening. In some embodiments, this circular path coulddescribe a full circle to fully release a portion of the lid. In otherembodiments the circular path could describe less than a full circle toleave a small “hinge” in the lid to retain the lid to the receptacle andkeep it from coming loose.

In some embodiments, the fixed or adjustable perforators may be springloaded as a means to prevent damage to the perforator or the dispenserif the frozen contents blocks the penetration of the needle. Thepressure of the spring load may be detected by the dispenser wheninterrupted by a receptacle or its frozen contents. The spring load andrelease may also be used to begin a sequence involving the melting anddiluting processes, for example, to trigger or terminate a supply ofheat, agitation, or a diluting agent. In some embodiments the needlesmay be attached to flexible tubing to provide for channels that may moveand adjust with movement, e.g., to accommodate planned agitation of thereceptacle as a means for enhancing the liquefaction of the frozencontents.

In some embodiments, the perforators are constructed of thermal stablepolymers. In other embodiments, the perforators are constructed of oneor more metals, such as stainless steel or aluminum. In someimplementations, regardless of the materials of construction, theperforators resist physical degradation when exposed to temperaturesbetween about −40° F. and about 300° F. In other embodiments, theperforators resist physical degradation when exposed to temperaturesbetween about 0° F. and about 250° F. The characteristics of the variousembodiments of the perforators for use on the outlet side of thedispenser and the characteristics of the various embodiments of theperforators for use on the inlet side of the dispenser apply equally toeach other.

As illustrated in FIGS. 10A-10E, the dispensing or drain orifice(s) orreliefs of the needle may be located at its point 1001, as in 1000A, orelsewhere and aligned axially as in FIG. 10A or to the sides 1004 as inFIGS. 10C and 10D, but in fluid communication with axial passage(s)1005, 1006, so the liquid injected into the receptacle can be directedaway from the center of the frozen liquid contents, possibly to helpmove or rotate the frozen liquid contents relative to the side walls ofthe receptacle. Concerns about needle strength and durability may beaddressed with a cruciform 1003 needle structure 1000B as in FIG. 10B.Example 10E might be used to first easily pierce the closed end of thereceptacle with the sharp point 1007 and then bear against the frozenliquid contents with the domed end 1008 without penetration, whilemelted/diluted liquid drains out of the side holes 1009 of the needle,wherein those side holes are positioned adjacent to the inside surfaceof the closed end of the receptacle. A screw like section of aperforation needle that spins may be used like an Archimedes pump todirect the flow of exiting fluid.

FIG. 4D illustrates one embodiment for a cassette or other device thatis capable of holding a variety of receptacle sizes and shapes to allowa wide range of beverages, soups, etc. to be used with a meltingapparatus.

FIG. 5 illustrates a range of receptacle sizes and shapes that could beaccommodated by the cassette of the machine (e.g., cassette 430 of FIG.4A). With different cassettes, each interchangeable with the original,but with differing hole sizes and shapes, an unlimited number ofdifferent receptacles can be accommodated by the brewer. It will berecognized by one skilled in the art that the process of filling,melting and diluting a frozen liquid content may be, in someembodiments, generally unaffected by the size or shape of thereceptacle.

The melting system may use any source of heat, motion, or a combinationthereof to expedite the liquefaction of the frozen liquid contents.Therefore, the melting system may include various sources of heat and/ormotion. Electromagnetic radiation (e.g., radio frequency energy,microwave energy, etc.), a heated coil, hot air, a thermo-electricplate, a heated liquid bath, steam, a chemical reaction and the like areall examples of possible sources of heat that may expedite the rate ofmelting. In addition, motion may be introduced using a centrifuge. Themotion may be one or more of rotational, rocking, whirling, rotary orlinear reciprocation, including agitation both back and forth and/or upand down (e.g., shaking), or a vibration platform or the like as a meansof expediting the melting rate. In another embodiment, the perforationsand pressures caused by an injected liquid may spin and move the frozenliquid content inside of the receptacle to create a desirableenvironment for liquefaction. One skilled in the art, however, willrecognize that various other physical action principles and mechanismstherefore can be used to expedite liquefaction. As described herein,manual or automatic (electronic) machine-based methods can be used toexpedite the melting and an increase in temperature of the frozen liquidcontents using various forms of motion, electricfrequency/electromagnetic energy, and/or heat. In such examples, theperforation needles may be given a range of motion so that they mayimplement or complement a range of motion. For example, in a centrifugesystem the needles may spin with the receptacle.

The system 400 includes internal electronic components, memory, and theappropriate controllers, along with programming instructions toautomatically create the desired food and/or beverage. The system 400can be given instructions by a user via a display or other knownmethods, e.g., wireless instructions from a handheld device.

The finished food or beverage serving can be made from the frozen liquidcontent of the receptacle at the temperature desired by the consumer,and via a method that is appropriate for direct consumption by theconsumer. In one embodiment, the frozen liquid content is melted anddiluted with a cool, or ambient temperature liquid, such that the frozenliquid content is melted and minimally heated for a beverage that isnormally consumed cold, like a juice, iced coffee, soda, etc.

In a specific example, represented in FIG. 11 , a receptacle withtapered sides 520 is punctured on the top and bottom of the receptacle,and an ambient-temperature liquid is injected via a top-puncturingneedle 1000D. As the liquid is injected into the receptacle, themachine-based apparatus spins, torques, and cooperates with thereceptacle in such a manner that the liquid 1101 in the receptacle flowsaway from the exit perforation(s) of the receptacle, formed by thebottom-puncturing needle 1000B. Thus, the diluting liquid may interactwith the frozen liquid content 190 for a longer duration of time withinthe receptacle and provide more thermal exchange between the frozencontent and diluting liquid. The exit of the liquid may be controlledeffectively by the flow of the water in, which will push water out whenthe pod nears or hits capacity or by decreasing or stopping theagitating motions. Optionally, the bottom-puncturing needle 1000Bdislodges the frozen liquid content from the bottom of the receptacle.

In some implementations of the embodiment shown in FIG. 11 , thedispensing system includes a motor or other known mechanism to spin thereceptacle 520 around an axis of rotation. In cooperation with theradius and geometry of the receptacle, the spinning motion imparted tothe liquid by the rotation around the axis overcomes the normal pull ofgravity on the liquid, thereby displacing the liquid along the sides ofthe receptacle and away from the bottom of the receptacle 1101. Thepuncture formed by needle 1000B is positioned to be in the empty spacecreated when the liquid is displaced.

In some embodiments, the inertia of the spinning liquid holds the liquidagainst the sidewall of the receptacle until the addition of new liquidinto the receptacle forces out a desired product or rotation speed isdecreased. In other words, the motion imparted to the receptacle and/orthe frozen liquid contents increases the flow path the liquid takes fromthe liquid inlet (via top-puncturing needle 1000D) to the liquid outlet(via bottom-puncturing needle 1000B). Without imparted motion, theinjected liquid would tend to take a direct path from inject to outlet;with imparted motion, the injected liquid travels along the outer wallsof the receptacle to the outlet. In such embodiments, the flow rate ofliquid entering the receptacle, in part, controls the amount of time themelted frozen content is in the receptacle. This residence timeinfluences the temperature exchange between the frozen content anddiluting liquid, and ultimately the temperature of the exiting liquidproduct. In some embodiments, the flow rate and pressure of the dilutingliquid supplied into the receptacle influence the amount of liquidpushed through the exit perforation(s) by overcoming the displacingforce imparted by the rotational motion applied to the receptacle for aclean, uniform flow out of the receptacle. In some embodiments, themotor, or other mechanism to drive the spinning of the receptacle ispositioned such that it is not an obstacle for supplied or exitingliquid. For example, a belt or gear system, or the like, is used todrive the receptacle around the axis without the need to position themotor or other mechanism above or below the receptacle.

Other examples of agitation/imparted motion are described herein and arewithin the scope of the invention. These other types of agitation alsoincrease the residence time of liquid in the receptacle and likewiseincrease the flow path of liquid through the receptacle from the liquidinlet to the liquid/product outlet. Advantageously, the liquid injectedinto the receptacle continues to flow within the receptacle duringagitation, and does so for a longer time relative to a lack ofagitation. This increases the heat transfer between the injected liquidand frozen contents.

In embodiments in which the frozen liquid content is displaced away fromthe bottom of the receptacle, the displacement may be accomplished bydomed needle 1000E. In some implementations, the displacement by thedomed needle is coupled with inversion of a dome (bistable or otherwise)mentioned above. In such case, the dome takes a new stable positioncurved inward toward the interior of the receptacle and holds the frozencontents away from the bottom of the receptacle. This can occur even ifthe domed needle 1000E does not remain in contact with the receptacle.In some embodiments, the domed needle 1000E pushes against thereceptacle bottom and creates a small displacement through bending orplastic deformation of the receptacle material. In some embodiments, adelayed action takes place to perforate the bottom of the receptaclewith the needle. This may occur simply by applying enough force to theneedle that the domed end ruptures the closed end.

In some embodiments, a secondary piercing head 1007, as shown in FIG.10E, emerges out of the domed needle 1000E. This piercing head easilycreates an initial puncture which is more easily expanded by the domedsurface 1008 of the needle, allowing the needle to move further into thereceptacle and enlarge the space around the periphery of the frozenliquid contents. In some embodiments, the emergence of the piercing head1007 of the needle is driven by a pneumatic cylinder. In someembodiments this movement forms a slight tear in the closed end of thereceptacle such that the domed end 1008 can expand the breach and easilypass through. Meanwhile, the piercing head 1007 can immediately retreatback into the needle body.

In some embodiments a component of the machine-based system used fordilution may include a liquid reserve, or a plurality thereof. In someembodiments the machine-based system may connect to a piping system thatdistributes a diluting agent from a larger liquid reserve or from anappropriate plumbing system, e.g., a filtered water system tied into abuilding's water supply. The diluting liquid may be water, however, anyliquid, including carbonated liquids, dairy liquids, or combinationsthereof, including any nutritive or non-nutritive liquids suitable forhuman consumption, may be used to dilute the frozen liquid contents to adesired composition. In some embodiments, the liquid for dilution may becarbonated to create soft drinks and the machine-based system mayinclude a carbonating component. In some embodiments, a diluting liquidmay be increased to a certain temperature or pressurized so as to meltthe frozen liquid contents with room temperature or chilled fluids tomake chilled or iced beverages. In some examples, the apparatus includesa refrigerated chamber for storing receptacles that may automaticallyload receptacles to a location to be created into a beverage without ahuman interacting with the receptacle. The previous example may becombined with a user interface (i.e., human machine interface) on themachine to load a desired receptacle in a vending style application.

In some embodiments for creating desired products that require dilution,a diluting agent is heated and/or allowed to flow to create a consumableliquid product of a desired flavor, potency, volume, temperature, andtexture in a just-in-time manner from the frozen liquid contents. Insome embodiments the diluting component may also act as the meltingcomponent. In some embodiments a diluting agent is heated and/or allowedto flow such that it complements an arbitrary melting component (e.g.,an electric heater) to create a consumable liquid product with desiredcharacteristics in a timely manner.

In some embodiments, water is heated to steam inside the dispenser andused as a means to externally heat the receptacle or the exit path forthe melted/diluted fluid. In some embodiments, this external heat may beused at different levels (quantities) or locations based on differentpossible objectives. For example, these objectives could include, butare not limited to: (a) melting just the outer layer of the frozenliquid contents to allow it to be more easily displaced away from theclosed end of the receptacle; (b) partially melting the bulk of thefrozen liquid contents as a supplement to lower temperature water usedfor melting/dilution especially for juices and other beverages where alower temperature final product is desired; (c) fully melting the frozenliquid contents as means for dispensing an undiluted melted liquid fromthe receptacle; (d) secondarily warming the melted/diluted beverage onceit leaves the receptacle as it flows through the exit channel to adrinking cup or mug or other container to heat the final beverage to amore desirable temperature; (e) heating one of the needles used toperforate the receptacle to facilitate some level of easy penetrationinto the frozen liquid contents. In some embodiments, steam used forthese purposes may be replaced by hot air or some other heated gasproduced either inside the dispenser body or externally usingelectricity or some combustible fuel such as natural gas. The use ofsteam or a hot gas may provide a greater level of control in theheating/melting of the frozen liquid contents which may be especiallyimportant when cold beverages or food products are desired as the finalconsumable. This process also assumes a means for carefullymetering/controlling the amount of steam or hot gas added to the totalenergy balance.

In some embodiments, a receptacle loaded into a dispenser is heatedbefore puncturing the receptacle bottom. This allows the frozen liquidcontent to remain in contact with the bottom and sidewalls of thereceptacle in order to increase the transfer of heat into the frozenliquid content. In such an implementation, the bottom of the receptacleis punctured after a selected time has passed, or after the receptaclehas reached a selected temperature. The additional delay in perforatingthe closed end/bottom of the receptacle is intended to allow some amountof melting/diluting fluid to enter the receptacle and fully surround thefrozen contents, filling any air gap between the sidewall and thedisplaced frozen content before an exit perforation is created. Doing soenables a continuation of the efficient transfer of heat from thereceiver into the liquid and the frozen content without the insulatingeffects of an air gap.

In one embodiment, as shown in FIG. 13A, a filterless receptacle 1310with frozen liquid content 1320 and a headspace 1306 is placed into asupporting tray 1302 and a heatable receiver 1301 of a dispenserdesigned to receive the receptacle so that the sidewalls of thereceptacle 1310 are in close contact with the walls of the receiver 1301and the flange of the receptacle is supported by tray 1302. When thedispenser's cover 1303 is closed by the user, the dispenser will captureand seat that receptacle in the close-fitting tray 1302 and receiver1301. The receiver is heatable using any of the techniques disclosedherein, and the close contact between the receiver walls and thereceptacle sidewalls enable the dispenser to efficiently heat thereceptacle's contents.

Referring to FIG. 13B, during closing of the receiver cover 1303, one ormore spring-loaded supply needles 1304 penetrate the top lid of thereceptacle, and one or more discharge needles 1200 penetrate thereceptacle's bottom. The actuation of the needles can be powered by themanual force of the user closing the dispenser's receiver, or,alternatively, one or both of these actions can be done by a controlledactuator. As illustrated in FIG. 13B, these needles may also be madecompliant with the help of a spring mechanism that limits the forceapplied by the needles in attempting to penetrate the frozen contents1320.

Referring to FIG. 10E, in some embodiments, a blunt tip 1008 on thedischarge needle 1000E displaces the receptacle's frozen liquid contentaway from the receptacle's closed bottom and into the tapered headspace,where it is supported by that same blunt-tipped discharge needle. In oneimplementation, this blunt discharge needle utilizes a T-shapedpassageway 1009 with openings in the sidewall of the needle locatedcloser to the receptacle bottom to allow dual discharge flow withoutinterference from the supported frozen liquid content, therebyemptying/venting the receptacle. In a different embodiment, the exitneedle is part of an assembly as shown in FIGS. 12A and 12B. The needleassembly is anchored by a part of the dispenser frame 1201 and comprisesa penetrator 1203, a compression spring 1202, a dome-shaped needlehousing 1204, and a fluid collecting tray 1205. When the needle assembly1200 first penetrates the closed end of the receptacle, the penetrator1203 bears against needle housing 1204 and seals it to prevent fluidexiting the receptacle. Subsequently, penetrator 1203 is forced upwardby spring 1202, opening a channel on the inside of needle housing 1204,allowing fluid to exit the receptacle and be collected by tray 1205, andthereafter dispensed into the user's cup.

Meanwhile, sharp tip(s) of the spring-loaded supply needle(s) 1304penetrate the receptacle's lid and come to rest against the recentlydisplaced frozen content 1320, where they may be stopped from furtherpenetration due to the interference between the needle tips and the topsurface of the frozen liquid content. The dispenser's heatable receiver1301 controllably warms and thaws the receptacle's frozen liquid contentthereby softening the recently repositioned frozen liquid content withinthe receptacle, readying the frozen liquid content for additionalthawing and/or dilution. In some embodiments, a measured portion ofliquid is injected into the receptacle simultaneously with needleinsertion to help transfer heat from the receiver through the gapcreated when the frozen contents was displaced away from the receptaclebottom (and, potentially, the sidewalls) to accelerate the meltingprocess.

In some embodiments, the injection of liquid into the receptacle isdelayed until the supply needle(s) move further into the frozen liquidcontent of the receptacle under the influence of the spring pressurebehind them as the frozen liquid content is softened due to the heating.This action further thaws and/or dilutes the frozen liquid content. Insome implementations, the contents controllably flow out the twinT-shaped passageway 1009 of the blunt discharge needle 1000E at thispoint. In other implementations, the discharge needle is closed alongits flow path as shown in FIG. 12A, thereby preventing contentsdischarge until the supply needle(s) reach a selected deployment depthas shown in FIG. 13C. Likewise, the injection of liquid is delayed toprevent receptacle rupture and/or overflow.

As the dispenser continues to thaw and dilute the frozen liquid content,the supply needle(s) extend fully by spring action to their fullydeployed length as shown in FIG. 13D, which stops short of contactingthe bottom of the receptacle. The supply needles may supply fluid withina range of temperatures and volumes as required by the food or beveragein the receptacle. In some embodiments, as shown in FIGS. 10C and 10D,these needles 1000C, 1000D have one or two internal passageways that are“L” shaped with an exit orifice that may direct the incoming fluidsomewhat tangentially to the sidewall of the receptacle. This geometryis intended to controllably agitate the receptacle's frozen liquidcontent to provide better mixing, a cleaner spent cup, and to speedthawing through such mechanical agitation. This agitation inside thefixed receptacle can be rotational in any direction, or tumbling in anever changing turbulent action, as designed by the needles' outlets andthe flow control valves of the dispenser. Moreover, in some embodiments,the liquid is supplied to the supply needles in an alternating fashionso as to introduce a back and forth motion, a rotational motion, orother turbulent action. Such a liquid supply can be accomplished by theuse of a multi-way valve controlled by the dispenser system. Furtherembodiments include a supply needle with a cruciform cross-sectionalshape (e.g., as described elsewhere herein) that engages the top of thefrozen liquid contents. The supply needle is motorized and directlyagitates the frozen liquid contents inside the receptacle.

Optionally, a locking mechanism keeps the springs compressed until acertain criteria is met, e.g., a quantity of heat has been applied tothe receptacle in order to sufficiently soften and liquefy the frozencontent such that the needles will penetrate the content. In a furtherimplementation, heat, in the form of gas, liquid, or steam is suppliedthrough the supply needle(s) upon initial deployment. The supply of gas,liquid, or steam is continued until the needle(s) are fully extended oruntil other criteria are met.

In some embodiments the variables of the melting component, or pluralitythereof, and dilution components, or plurality thereof, are programmableand adjustable to create a wider range of characteristics for creatingbeverages and liquid food products. For example, decreasing thetemperature of a pressurized liquid used for dilution will decrease thetemperature of a consumable liquid product created by the machine-basedsystem and apparatus.

In one specific example embodiment, presented for illustrative purposesonly, a frozen 1 oz. coffee extract with a TDS of 12, may be packaged ina receptacle and accommodated by a machine-based system that expeditesthe melting of the frozen liquid contents by delivering heated water tothe receptacle to melt and dilute the contents thereof with 7 ounces of200 degree water to create a single-serving of 8 ounces of a hot coffeebeverage with a TDS of 1.5 at a desired temperature. In someembodiments, other measurement techniques can be used in place of TDS,such as BRIX. Alternatively, with adjustable dilution settings, thefrozen coffee extract may be melted and diluted with only 1 ounce ofwater to create a 2 ounce espresso style beverage of a desiredtemperature with a TDS of approximately 6. Furthermore, the receptaclemay only be heated such that the frozen extract barely melts, such thatit may be added to a consumer provided liquid, like milk for a chilledor iced latte or another iced beverage like a juice, iced coffee or tea.

In some embodiments, the variables defining the frozen liquid contents,like temperature, volume, shape, size, portionality, etc. can also beadjusted during manufacturing of the liquids used to freeze the frozenliquid contents to better facilitate making a desired food or beveragefrom a machine-based system with limited machine settings/controls. Forexample, freezing a larger volume of a less potent fluid as the basisfor the frozen liquid contents in a given receptacle may be used tocreate a beverage of a lower temperature, ceteris paribus.

It is also contemplated as part of the techniques described herein thatthe machine-based system includes sensor technology that canautomatically adjust the settings of the melting and/or dilutioncomponent to produce a desired beverage or liquid food outcome. Theperforation properties may also be programmable or automaticallyestablished using sensor technology that assists in recognizing thereceptacle type, size, contents, bottom location and other properties.This sensor technology may also be used to inhibit certain settings frombeing applied. For example, a frozen broth concentrate receptacle mayinhibit a consumer from implementing settings that would over-dilute andwaste the product. As another example, a frozen broth concentratereceptacle may inhibit a consumer from implementing settings that wouldoverheat, for example, an orange juice concentrate. In some embodiments,this sensor technology assists in creating a desirable product andeliminating human error. In some embodiments this sensor method isenabled using specific geometry formed into the receptacle. For example,as shown in FIGS. 8 and 9 , an indentation of a specific length could bephysically or optically sensed by the dispensing machine and thismeasurement used to convey information about the contents of thereceptacle and thereby allow the dispensing machine to automaticallychoose the right melting/dilution process. Physical modifications to theshape of the receptacle as exemplified in FIGS. 8 and 9 may also assistin the mixing of the dilution liquid injected into the receptacle andthereby help to speed the liquefaction of the frozen liquid contents.

In some embodiments, the melting and/or diluting controls may beprogrammable or established using bar coded instructions or other visualdata system on the receptacle to achieve a product satisfying aconsumer's individual preference. The machine-based system may detectand read bar codes, data glyphs, QR Codes, patterns, external markings,RFID tags, magnetic strips, or other machine-readable labels using theappropriate sensors. In some embodiments at least one criterion of thereceptacle or frozen liquid contents establishes or inhibits thesettings of the accommodating machine-based system for creating adesired product. These criteria might include, but are not limited to,weight, color, shape, structure, and temperature. In some embodimentsthe machine-based system may include a thermocouple to detect thetemperature of the frozen liquid contents and/or its receptacle andautomatically adjust its settings to create a beverage of a desiredflavor, strength, volume, temperature, and texture. This may includedisabling the dilution function and engaging a melting component thatdoes not dispense a liquid. Furthermore, the consumer may enter an exactdesirable characteristic, like temperature or potency, and themachine-based system may use this in combination with available sensortechnology to achieve desired parameters.

In addition, the machine-based system may be designed to createdesirable beverage and liquid food products from a variety of receptaclestyles, receptacle sizes and frozen liquid contents. In someembodiments, the machine-based system may include a mechanical functionto distinguish and limit controls and settings for beverage creation.

Furthermore, the machine based system may include a mechanical functionthat is necessary for product creation for different receptacle andfrozen liquid content types. In some embodiments the frozen liquidcontents may be crushed or macerated by the machine-based system toincrease the surface area of the frozen liquid contents to increasemelting rates. This mechanical function may be initiated manually by theconsumer or automatically implemented by a sensor trigger. For example,it has been contemplated herein that dislodging frozen liquid contentsfrom receptacle walls may create issues and make it difficult to piercethe receptacle where it is in contact with the frozen liquid contents.In some embodiments the machine may recognize the specific frozenreceptacle type, discriminating it from other frozen receptacles, usingsensed criteria, like weight or temperature, and mechanically adjust thereceptacle so it can be perforated in a specific location where nofrozen liquid content is in contact with the receptacle. This mayinclude flipping the receptacle upside down.

In some embodiments the machine-based system melts and dilutes thefrozen liquid contents by flowing or pushing a specific amount ofliquid, which may be heated and pressurized, through the receptacle tocompletely melt and dilute the frozen liquid contents to a desiredflavor, strength, volume, temperature, and texture. In combination withthis embodiment, the machine-based system may include an additionalmelting component, such as a receptacle heater, or heated punctureneedles or the like, to facilitate the creation of a desired consumableliquid that the consumer does not desire to dilute. In some embodimentsthe flowing liquid melts the entire frozen liquid contents to eliminatewaste and rinses the receptacle of any residue or contaminants as partof the melting or dilution process so that a receptacle of a homogeneousmaterial is rendered free of grinds, residues, or filters, and is thusconverted into an easily recyclable form. In some embodiments, focusedspecifically on recycling, the manufacturer would introduce a depositrequirement for each receptacle to encourage its return to the point ofsale for a deposit refund.

In some embodiments the frozen food or beverage liquid is packaged tohandle a flowing diluting liquid without an overflow. Again, thisspecific apparatus may involve freezing the food or beverage liquid intospecific geometric shapes, structures, and proportionality to providenecessary flow paths through the receptacle to its exit.

For clarity, illustrative embodiments for different aspects of thesystem have been described with respect to the type and design of thereceptacle, the nature of the frozen liquid content, the means formelting and/or diluting the frozen liquid content, and the deliverymechanism applied to the resulting liquid to create a consumable food orbeverage on a just-in-time, consistent basis at the desired flavor,potency, volume, temperature, and texture. It will be apparent to oneskilled in the art that these various options for receptacle type, formand characteristics of the frozen liquid content, mechanisms for meltingand/or diluting the frozen liquid contents, and means for delivery ofthe liquefied contents can be combined in many different ways to createa pleasing final product with specific characteristics which can beconveniently enjoyed by the consumer.

It is clear from the above description that embodiments of the inventionprovide a filterless single chamber mixing vessel containing a frozenliquid contents that enables the creation of a diverse variety of foodand beverage products. The receptacles are maintained as a sealedenvironment, optionally including an oxygen barrier, that preserves thefinal product, or a concentrated version thereof, in a frozen stateuntil a user decides to create the product. Moreover, even afterperforation by one or more inlets or outlets, the receptacle remainsessentially a sealed mixing chamber in which a product is created bymixing a fluid or fluids with the frozen liquid contents while alsoproviding for a controlled fluid outlet. Upon insertion into any of thedispenser embodiments described herein or other known single servingbeverage makers/brewing systems, the receptacle functions as afilterless single chamber mixing vessel by accepting a melting and/ordiluting liquid (e.g., water) that melts and combines with the frozenliquid contents to produce the desired product. Such use of embodimentsof the receptacles described herein enables existing beveragemakers/brewing systems to function as a dispenser without requiring amodification to the system, thereby allowing a user flexibility to usehis or her existing system as a dispenser or brewer.

In some embodiments, the dispenser manipulates the timing, sequence,amount, and manner of the heating of, the agitation of, and/or theaddition of dilution liquid to the receptacle and/or frozen liquidcontents to control the melting and/or thawing of the frozen liquidcontents. Optionally, the dispenser manipulates the temperature of thedilution liquid added to the receptacle and/or final product. In someimplementations, the dispenser causes at least portions of the frozenliquid contents to transition from a frozen phase to a liquid phasewhile reducing or preventing the transition of the liquid and/or solidphases to a gaseous phase. For example, the dispenser can expose thereceptacle and/or the frozen liquid contents to a non-diluting source ofheat (i.e., a source of heat other than injecting a liquid into theinterior of the receptacle that dilutes any melted frozen liquidcontents) at a rate or a flux that causes the frozen liquid contents tomelt but does not cause the resulting liquid to boil. Similarly, thedispenser can control the total amount of non-diluting heat supplied tothe receptacle and/or frozen liquid contents during a multi-step food orbeverage creation process so as to achieve an intermediate averagetemperature of the contents. When the dispenser then supplies apredetermined amount of diluting liquid at a known temperature to theinterior of the receptacle, the diluting liquid and contents combine toform the product of the desired temperature and volume.

As described herein, embodiments of the dispenser can determine certaincharacteristics of the receptacle, frozen liquid contents, and/or finalintended food or beverage product based on machine-readable labels.Likewise as described herein, implementations of the dispenser includesensors to gather data about the present state of the receptacles and/orcontents therein. Further still, the dispenser can contain sensors todetermine the temperature of a heated and/or ambient dilution liquid.Based on the available sensor information and characteristics gatheredfrom the machine-readable labels, the dispenser modulates the heat,agitation, and dilution actions described herein to achieve the desiredheating profile as well as a final product having the desiredcharacteristics. For example, while supplying heat and agitation to areceptacle, the dispenser can monitor the temperature of the receptacleand modulate the heat supplied to ensure that its temperature remainsbelow a predetermined value (e.g., below boiling or below a temperatureat which the content's quality would be degraded). In a further example,the dispenser can supply heat in an intermittent fashion, either with orwithout agitation, with pauses in heating to allow the entire contentsof the receptacle to equilibrate, again either with or without agitationduring the pauses. Doing so is expected to increase the accuracy of thetemperature reading with respect to the entire receptacle contents andincrease the likelihood of generating “hot spots” in the receptacle.Likewise, the dispenser can control the frequency of the agitation(e.g., the speed at which vibration, reciprocation, etc. is modulated)depending on the characteristics of the receptacle, frozen liquidcontents, and/or final intended food or beverage product.

In addition to monitoring the temperature of the receptacle and/or theentire contents of the receptacle, the dispenser can monitor thepressure inside of the receptacle. For example, before applying heat tothe receptacle, the dispenser can perforate the receptacle with a needlehaving a lumen in fluid communication with a pressure sensor. Then,during a heating step, the dispenser can modulate the rate at which heatis applied to the receptacle based on detecting pressure increasesinside the receptacle. In an alternative example, the dispenser candispose a transducer (e.g., a stress gauge or a displacement gauge) incontact with a portion of the exterior of the receptacle. Thetransducer, such as a capacitive displacement sensor, can detectpressure increases inside the receptacle based on portions of thereceptacle bulging during heating.

For example, the dispenser could heat the entire contents of areceptacle to an average temperature that remains relatively cold,potentially forming a partially melted “slush”, based on detectinginformation that identifies the receptacle as containing a high TDSorange juice frozen liquid contents. The dispenser can then add theappropriate amount of an ambient temperature dilution liquid to create achilled orange juice of the correct concentration. In this example, thedispenser softens the frozen liquid contents to enable easy mixing ofthe contents and dilution liquid, but the dispenser does not overheatthe contents. This approach takes advantage of the relatively lowerfreezing point of the high TDS content to provide a chilling effect onthe incoming ambient dilution liquid. Any or all of the steps of theprocess can include agitation.

In certain embodiments, sufficient open space remains within the mixingchamber of the receptacle to allow the frozen liquid contents to bedisplaced into the open space of the chamber so as to not interfere withliquid inlets and outlets (e.g., needles) and/or incoming and outgoingliquid. In some embodiments, the frozen liquid contents in thereceptacle occupy less than half of the total volume of the mixingchamber of the receptacle. In other embodiments, the frozen liquidcontents occupy more than half of the total volume of the mixingchamber.

As described above, in certain embodiments, the frozen liquid contentsare dislodged from the bottom of the receptacle by the action of aneedle. Tapered sidewalls of the receptacle help the frozen liquidcontents release from the bottom portion of the receptacle. The taperedsidewalls also provide for a flow path around the frozen liquid contentsafter the contents have been displaced into what was formerly the emptyspace of the receptacle. Another factor impacting the amount of forcerequired to dislodge the frozen liquid contents is the size of thefrozen liquid content itself. Relatively smaller frozen liquid contentswill be in contact with relatively less interior surface area of thechamber, thereby reducing the amount of force required to dislodge thecontents relative to larger frozen liquid contents.

Controlling the size of the frozen liquid contents imparts additionalbenefits. For example, by maintaining the frozen liquid contents sizewithin a selected range or below a particular threshold, embodiments ofthe invention ensure that the frozen liquid contents are completelymelted before the full volume of dilution liquid has passed through thereceptacle. In such embodiments, the fluid passing through thereceptacle after the frozen liquid contents have melted washes theinterior of the receptacle and product outlet flow path clean ofresidue. Doing so both increases the recyclability of the receptacle andreduces contamination of the product outlet flow path. In addition, bykeeping the size of the frozen liquid contents within a range or below acertain threshold, one can ensure that the final product achieves theproper temperature range for the particular product.

Meanwhile, controlling the degree of concentration of the frozen liquidcontents (e.g., as measured by TDS and/or Brix) enables one to ensureproper final product strength in view of the size of the frozen liquidcontent and the amount of dilution liquid used. Relatively larger frozenliquid contents require a lower degree of concentration than relativelysmaller frozen liquid contents for the same final product using the samedilution and melting liquid. The desired final product concentrationalso determines the degree of concentration of the frozen liquidcontents, e.g., a 2 oz. espresso with a final TDS of 6 will require arelatively more concentrated frozen liquid contents than would an 8 oz.cup of coffee with a final TDS of 1.25. Further still, in someembodiments, the degree of concentration of the frozen liquid contentsis high enough to enable the size of the frozen liquid contents to besmall enough to permit an outlet needle from a dispenser or known brewerto pass through the frozen liquid contents, thereby enabling the needleto access the open space above the frozen liquid contents withoutinterference from the contents. Thus, certain embodiments of thereceptacles disclosed herein have a size and shape to fit in knownsingle serving brewing systems that have known outlet needle penetrationdepths. Because these dimensions are known, these embodiments havefrozen liquid contents that have a degree of concentration that enablesthe contents to be in contact with substantially the entire end layer ofthe receptacle while having a contents height that is less than thepenetration depth of the needle. In this way, embodiments of theinvention are customized for known single serving brewing systems basedon the known dimensions and characteristics of those systems.

As mentioned above, certain embodiments described herein include areceptacle with a frozen liquid content disposed inside the receptaclecavity that is in contact with the bottom of the receptacle (the endlayer). In these embodiments, a needle from a dispenser or brewingmachine perforates the bottom of the receptacle and lifts frozen liquidcontent into the otherwise unoccupied space inside the receptacle. Inorder for the frozen liquid contents to be displaced by the needle, thefrozen liquid contents must be of sufficient hardness (at itstemperature when placed into the dispenser/brewer) to prevent the needlefrom embedding in the frozen liquid contents. If the needle embeds intothe frozen liquid contents, the contents are not displaced from thebottom layer of the receptacle, and the exit flow path for the finalproduct formed by the mixing of the frozen liquid contents and incomingliquid is blocked. Similarly, if the frozen liquid contents bends at thepoint of impact of the needle, the frozen liquid contents will not bereleased from the inner walls of the receptacle chamber. This, too, willresult in blockage of the exit flow path. Thus, in certain embodimentsof the invention, the frozen liquid contents is sufficiently hard thatwhen force is applied to it with a dispenser needle (e.g., a hollowcylindrical needle of about 2.5 mm outer diameter with about a 4 mm longdiagonal pointed section), the frozen liquid contents is dislodged fromthe inner surface of the receptacle rather than the needle embeddinginto the contents or the contents deflecting away from the needlewithout dislodging. The illustrative dimensions of the needle givenabove is not limiting, as the frozen liquid contents of theseembodiments with work with other needle dimensions, including those withlarger or smaller bores as well as those with non-cylindricalcross-sections.

It is believed that hardness levels of between about 1 and about 6 onthe Mohs scale (at between about 0° F. and about 32° F.) providesufficient hardness to dislodge from the inner surface of thereceptacles described herein rather than experience the undesirableeffects set forth above. Thus, certain embodiments of the invention havea hardness of between about 1 and 5 on the Mohs scale at between about0° F. and about 32° F. Other embodiments of the invention have ahardness of between about 1 and 4 on the Mohs scale at between about 0°F. and about 32° F. Still other embodiments of the invention have ahardness of between about 1 and 3 on the Mohs scale at between about 0°F. and about 32° F. Further embodiments of the invention have a hardnessof between about 1 and 2 on the Mohs scale at between about 0° F. andabout 32° F. Certain embodiments of the invention have a hardness ofbetween about 0.5 and 1.5 on the Mohs scale at between about 0° F. andabout 32° F. Other embodiments of the invention have a hardness ofbetween about 1.5 and 2.5 on the Mohs scale at between about 0° F. andabout 32° F. Yet further embodiments of the invention have a hardness ofbetween about 0.75 and 1.25 on the Mohs scale at between about 0° F. andabout 32° F. In some embodiments, the hardness of the frozen liquidcontents is enhanced by the addition of food-grade hardening agents,e.g., thickeners, stabilizers, and emulsifiers. Other examples includeguar gum, agars, alginates, carrageenans, gum Arabic, locust bean gum,pectin, sodium carboxymethyl cellulose, various starches, and xanthangum.

In certain embodiments, the frozen liquid contents will be of such aconcentration (i.e., relatively high % TDS) that the contents will notbe hard enough to be displaced by a dispenser or brewer needle, due tofreezing point depression caused by, e.g., high sugar levels. Rather,the needle will embed into the contents, the contents will clog theneedle, or the contents will flex away from the needle withoutdislodging from the receptacle chamber inner walls. FIG. 14A illustratesa side cross-section view of a receptacle 1400 with an inner platform1405. The platform 1405 is located between an end layer 1410 of thereceptacle 1400 and a frozen liquid contents 1415. In FIG. 14 A, theplatform 1405 is shown spaced apart from end layer 1410 and frozenliquid contents 1415. In some embodiments, the platform 1405 rests onand is in contact with the end layer 1410, and the frozen liquidcontents 1415 is in contact with the platform 1405 and, optionally, aportion of the end layer 1410. Herein, this platform may also bereferred to as a “platform”, a “pusher plate”, a “displacement disc”, orsimply a “disc”.

FIG. 14B illustrates a side cross-sectional view of the receptacle 1400with the inner platform 1405 displaced away from the end layer 1410 andsupporting the dislodged frozen liquid contents 1415. As shown in thefigure, dispenser/brewer needle 1420 perforates the end layer 1410, butdoes not perforate platform 1405. Rather, the needle 1420 contacts theplatform 1405 and dislodges the frozen liquid contents from the innersurface of the receptacle 1400. Thus, the platform 1405 enables frozenliquid contents to be displaced by a needle that on their own mayotherwise lack sufficient hardness to be displaced by the needle. Thevarious platforms described herein may also be used with frozen liquidcontents that have sufficient hardness alone to be displaced throughcontact with a needle. Using a platform inside of the receptacle with awide range of frozen liquid contents provides uniform displacementbehavior. Platform 1405 is, optionally, made from the same material asreceptacle 1400 to maintain the receptacle's recyclability (e.g.,aluminum), but it may also be made from a different material than thereceptacle to enhance its suitability for contact with food or for cost.The platform 1405 can be made harder than end layer 1410 by hardeningtreatments known in the art, and/or platform 1405 can be made of thickermaterial that end layer 1410. The platform may be made of a materialknown to have a higher or lower coefficient of friction than thereceptacle material to aid in creating bypass flow around it or thru it.

FIGS. 14A and 14B show the platform 1405 as a flat disc. However, otherembodiments include those shown in FIGS. 14C and 14D. FIG. 14C shows aplatform 1430 with a scalloped circumference 1435, and FIG. 14D shows ascalloped platform 1440 with an overflow tube 1445. The overflow tube1445 forms a channel between the space above a frozen liquid contentsdisposed on the platform 1440 and the space created below the platformwhen the platform is raised by the dispenser needle (e.g., as in needle1420 of FIG. 14B) or a compressed gas or liquid. Further detailsdescribing the overflow tube 1445 follow below. Still furtherembodiments include platforms that are slightly concave or convex(relative to the end layer), frusto-conical, corrugated, have stampedconvolutions, or possess other non-flat profiles. Such embodimentsreduce the likelihood that the platform would adhere to the end layerand/or reduce the likelihood of acting as a barrier to liquid flowthrough an outlet formed in the end layer. Platforms 1430 and 1440 maybe flat or possess any other non-flat profile. Platforms 1430 and 1440may have smooth edges or scalloped edges as shown in the figure.

FIG. 15A shows an embodiment of a receptacle 1500 with a compound draftangle. Receptacle 1500 has a top flange diameter 1505 of about 2.00inches, a bottom transition diameter 1510 of about 1.44 inches, and anend layer diameter 1515 of about 1.26 inches. Receptacle 1500 has aheight 1520 of about 1.72 inches. Receptacle 1500 has a sidewall with acompound draft angle with a transition point 1525 that occurs about 0.75inches from the end layer (1530). Above the transition point 1525, thedraft angle 1535 is about 2.5 degrees, while the draft angle below thetransition point 1540 is about 8 degrees. The greater draft angle in thelower portion of the sidewall facilitates release of frozen liquidcontent that rests on the end layer of the receptacle. Meanwhile, thelower draft angle of the upper section aids in securing the receptaclein a receiver of a dispenser and/or known single serving brewer.

FIG. 15B shows Detail A of the receptacle 1500 of FIG. 15A. This figureillustrates a rolled lip 1545 potion of the flange of the receptacle aswell as an indentation 1550 that sits below the highest part of therolled lip 1545. Certain materials, e.g., aluminum, will retain a sharpedge when machined or stamped. Such an edge can present a safety hazardto users of receptacles having such an edge. Rolled lip 1545 tucks theedge of the flange under the body of the flange, thereby protecting theuser from any remaining sharp edges. Meanwhile, indentation 1550 allowsa lid to be mounted to the flange body and maintain the top lid surfacebelow the highest part of the rolled lip 1545. The specific sizes setforth above for receptacle 1500 can be varied while maintaining thecompound draft angle and remain within the scope of the invention.

FIG. 16 illustrates a side cross-sectional view of a receptacle 1600with a platform 1605 having an overflow tube 1610. Although platform1605 is shown as a flat disc, it can be any of the shapes describedherein. The receptacle has a flange diameter 1615 of about 2.00 inchesand a height 1620 of about 1.72 inches. Receptacle 1600 has a sidewallwith a compound draft angle with a transition point 1625 that occursabout 0.75 inches from the end layer (1630). Above the transition point1625, the draft angle 1635 is about 2.5 degrees, while the draft anglebelow the transition point 1640 is about 15 degrees. The end layer ofthe receptacle 1600 has a stepped portion 1645 that accommodates theplatform 1605 with little to no space between the outer circumference ofthe platform 1605 and the step. In the illustrated embodiment, thediameter of the platform 1650 and the stepped feature is about 1.16inches. The close fit between the platform 1605 and the stepped portion1645 reduces or prevents liquid contents from settling between theplatform 1605 and the end layer 1675 before the contents is frozen,which could increase the amount of force required to dislodge the frozenliquid contents from the inner surface of the receptacle 1600 and allowfrozen contents to flow into the bottom of the overflow tube 1610blocking intended flow during the melting/dispense cycle. The close fitbetween the platform 1605 and the stepped portion 1645 acts to hold theplatform firmly in place during liquid filling and until the liquidcontents are frozen.

In other embodiments (not shown), a further stepped region exists belowthe platform 1605 to create a space between the platform 1605 and theend layer 1675 that is not occupied by frozen liquid contents. Thisspace allows fluid to flow down the overflow tube 1610 and into thespace between the platform and end layer in order to exit the receptaclethrough a perforation in the end layer.

In FIG. 16 , the platform 1605 and overflow tube 1610 are show incross-hatch to distinguish the platform and overflow tube from the endlayer (bottom) 1675 of the receptacle 1600. The overflow tube 1610 isdisposed inboard of a point about 0.50 inches from the receptacle centerline (1655). This point is a common entrance point for one or moreoutflow needles of known single-serving and multi-serving brewers. Thus,when the outlet needle penetrates the end layer of the receptacle, theneedle will lift the platform 1605 and frozen liquid contents (notshown) in a manner similar to that described for the embodiment in FIG.14B rather than the needle entering the channel of the overflow tube1610. The top of the overflow tube 1660 is above a nominal fill line1665 for frozen liquid contents at about 0.50 inches from the topsurface of the platform (1670). The specific sizes set forth above forreceptacle 1600 can be varied while maintaining the compound draft angleand remain within the scope of the invention.

FIG. 17 shows a receptacle 1700 with a platform 1705 and overflow tube1710; a frozen liquid contents 1715 rests on the top surface of theplatform 1705. This figure shows a needle 1720 of a dispenser or knownsingle serving brewer that has penetrated an end layer 1725 of thereceptacle 1700 and lifted the platform and frozen liquid contents. Theoverflow tube 1710 provides an alternate flow path for liquid injectedinto the receptacle 1700 (e.g., by an inlet needle that perforates a toplid (not shown)) in the event that the flow path around the frozenliquid contents becomes blocked or is insufficient for the incomingliquid flow. Rather than the excess liquid building-up inside thereceptacle and overflowing outside the mixing chamber of the receptacle1700, when the liquid level reaches the top inlet 1730 of the overflowtube 1710, the liquid is channeled to the space below the platform 1705so it may exit via the needle 1720. During this process, water that isbeing introduced into the receptacle via a needle penetrating the lidmust also be prevented from passing directly into the overflow tube,thereby defeating its purpose of melting and diluting the frozencontents. In certain embodiments, a needle geometry similar to thatshown in FIG. 10C or 10D would be effective at directing the incomingwater away from overflow tube 1610 and constructively toward thesidewalls of the receptacle.

FIG. 18 illustrates a receptacle 1800 with a raised circular protrusion1826 (in essence, providing a depression 1825) in the end layer and anannular platform 1805 shown in a slightly raised position. This platformis designed and sized such that its center circular opening 1806 fitstightly around the raised protrusion 1826 in the receptacle duringnormal liquid filling and handling, with the friction created by a lightinterference fit between the two components holding the platform inplace during filling and until the liquid contents have frozen. Duringuse, the needle which penetrates the bottom of the receptacle dislodgesthe annular platform and helps displace the frozen contents to a secondposition. This annular shape for the platform serves the secondaryfunction of reducing its weight and, when the platform is made from adifferent material than the receptacle, allowing the receptacle as awhole to be more easily recycled. For example, if a high densitypolyethylene (HDPE) platform is used in an aluminum receptacle, therecyclability of the entire assembly may be maintained, withoutrequiring the platform to be separated from the receptacle, if the totalpercentage of HDPE in the receptacle assembly is kept below a thresholdamount. In this embodiment, the size of the annular opening in theplatform may be increased to the edge of the needle perforation zone tomaximize weight reduction. Alternatively, the disc might be a hybriddesign as, for example, a metallic washer shape enclosed in a plasticapproved by the FDA for contact with food.

In some implementations, rather than, or in addition to, theinterference fit between the platform and the raised protrusion 1826,the platform can have an interference fit between the circumferentialedge of the platform and the sidewall of the receptacle. In theseimplementations, the platform can be any of the embodiments describedherein.

FIG. 19 illustrates a receptacle 1900 with a domed end layer 1926 and amatching platform 1905 whose convex surface section 1906 is sized anddesigned to match the outward extension of the dome in the receptacle.Prior to insertion into a dispensing machine, or as part of the machineoperation, the receptacle dome 1926 is intended to be pushed inwardwhere it achieves a new stable position and holds or displaces thefrozen contents into a second position with flow paths around itsexterior surfaces. The convex surface 1906 of the platform is pushedupward, but does not reverse its position, i.e., does not become concaveas seen from the closed end of the receptacle. Thus, in this embodimentthe platform supports partially frozen or gummy/flexible contents inthis raised position by bearing against the now inwardly protrudingreceptacle dome on the bottom and carrying the frozen contents above.Needle penetration from the bottom of the receptacle may assist in thedisplacement of the platform and the frozen contents. And as with otherembodiments, the platform prevents the needle from being clogged by thepartially frozen contents.

FIG. 20A illustrates the operation of receptacle 1900 shown in FIG. 19 .In its initial position, domed end layer 1926 is in the convexconfiguration, which conforms to the convex surface of the platform1905. In its second position, shown in FIG. 20B, domed end layer 1926 isin the concave configuration. A portion of the concave end layerinterferes with the still convex portion of the platform 1905 to createa space 1930 between the bottom surface of platform 1905 and the topsurface of the end layer 1926. This interference also creates andmaintains flow paths 1935 around the frozen contents that rests upon thetop of the platform 1935. Either or both of the domed sections of theend layer and platform can be bistable.

FIG. 21 illustrates a receptacle 2100 with a flat end layer and a flatplatform 2106 supporting partially melted frozen contents 2126, held inplace by the bottom needle 2105. This figure clearly shows a flow path2128 around the frozen contents when the platform is raised off the endlayer. In this particular embodiment, the frozen content is seen to haveshifted slightly off-center of the platform and coming to rest againstthe side of the receptacle. In some embodiments, to prevent the platformfrom moving out of place, the edge 2127 in contact with the end layer isphysically attached with a hinge mechanism such as a small spot weld(e.g., to create a living hinge). This embodiment may also require akeying feature such that the bottom needle always penetrates the endlayer diametrically opposite the hinge.

In some embodiments, the platform includes ridges in order to increasethe section moment of inertia of the platform to thereby increase theplatform's resistance to deformation. As shown in FIG. 22A, one suchembodiment 2205 includes single direction ridges 2210. Anotherembodiment 2215, shown in FIG. 22B, includes a cross-hatch pattern 2220.FIG. 22C shows an platform 2225 that includes sandwich structures 2230with ridges set at perpendicular orientations to provide increasedbending stiffness in all directions. A similar effect can be achieved bylayering materials having anisotropic rigidity. FIG. 22D shows aplatform 2235 that includes radial ridge structures 2240. In someimplementations, the ridge height is kept sufficiently low and theridges are spaced sufficient close together so as to not interlock witha needle contacting the platform.

In further embodiments, the platform is maintained above the end layerso that some amount of the frozen contents is between the bottom surfaceof the platform and the top surface of the end layer. In theseembodiments, the distance between the bottom surface of the platform andthe top surface of the end layer is kept to a maximum such that a needleor other perforator is able to pass through the frozen contents, contactthe platform, and still lift the platform sufficiently to create flowpaths around the frozen contents.

In other implementations, the platform includes embossing or slightlyraised features which assist with melting and mixing the frozen contentswith a melting liquid introduced into the receptacle when the assemblyis rotated or agitated. In certain implementations, a perforator isdesigned to engage the platform to impart agitation or a stirringaction. For example, as shown in FIG. 23 the top surface of a platform2300 may have “tabs” 2305 that extend perpendicular to the top surfaceof the platform. Platform 2300 also has a keyed opening 2310 along itscentral axis. Keyed opening 2310 is shown in the figure as passingthrough the entire platform, however, in some embodiments, the openingis closed on the top surface of the platform that is in contact with thefrozen liquid contents to prevent frozen contents from filling theopening. FIG. 24 shows an underside view of the platform 2300. Aperforator 2400 has a keyed portion 2405 that has a shape that iscomplementary to keyed opening 2310 of the platform. FIG. 25 shows thekeyed portion 2405 of the perforator engaged with the keyed openingfeature 2310 of the platform 2300. This allows the perforator to imparta spinning, reciprocal, or other agitating motion to the platform by wayof a drive mechanism such that the perforator spins the platform andfrozen contents within the receptacle.

FIG. 26 shows a cross-sectional view of a receptacle 2600 with a frozenliquid contents 2605 disposed on a platform 2610 that has tabs and akeyed opening, as described above. The figure shows a perforator 2615with a keyed portion 2620 positioned to perforate an end layer of thereceptacle 2600. FIG. 27 shows a cross-section view of the receptacle2600, with frozen liquid contents 2605, disposed on platform 2610.Perforator 2615 has perforated the end layer of the receptacle andengaged the platform via the keyed opening of the platform and keyedportion of the perforator (at 2700). The perforator 2615 has raised theplatform 2610 and frozen liquid contents 2605 to create space betweenthe platform and end layer as well as to create flow paths around thefrozen liquid contents 2705. When the receptacle 2600 and/or platform2610 are rotated about its central axis by the perforator 2615, the tabsencourage the frozen contents 2605 to spin with the receptacle. As thefrozen contents releases from the platform and liquid covers the topsurface of the platform, the tabs introduce turbulence in the liquid andencourage mixing of still frozen portions of the frozen contents and theliquid in the receptacle. FIG. 28 shows receptacle 2600 of FIG. 27 aftersome of the frozen liquid contents 2605 has melted, exposing a portionof tabs 2805 embedded in the frozen contents.

FIG. 29A shows a perforator 2900 with an opening 2905 along the lengthof the perforator. Opening 2905 communicates with one or more lumens inthe perforator (not shown) to allow liquid to exit the receptacle via anopening 2910 at the base of the perforator 2900 that communicated withthe lumen(s). Similarly, FIG. 29B shows a perforator 2920 that haschannels 2925 on the outside of the perforator to enable liquid to exitthe receptacles along the channels.

FIG. 30A shows a perforator 3000 that has a cruciform keyed portion3005, side openings 3010, and a top opening 3015. Side openings 3010 andtop opening 3015 communicate with a central lumen that passes throughthe perforator to a base of the perforator. FIG. 30B shows a perforator3020 that also has a cruciform keyed portion 3025. Perforator 3020 haschannels 3030 along the outside surface of the perforator. FIG. 30Cshows a tapered perforator 3040 with a greater dimension at its distalend 3045 relative to the dimension at its proximate end 3050. Perforator3040 also has a cruciform keyed portion 3055. Such a perforator wouldcreate a hole in an end layer of a receptacle that is larger than theproximate portion of the perforator, thereby leaving a flow path aroundthe perforator for liquid to exit the receptacle. Similarly, FIG. 30Dshows a perforator 3060 that has a cruciform head portion 3065 that hasa larger dimension than a stem portion 3070. The head portion 3065creates an perforation that is larger than the stem's diameter, creatinga flow path for liquid to exit a receptacle. The cruciform portions ofthe above described perforators are designed to engage cruciform-shapedopening in platforms.

FIG. 31 illustrates a side cross-section view of a receptacle 3100 withan inner platform 3105 that is in the form of a cup with a raised lip3107. Raised lip 3107 is shown spaced apart from frozen liquid contents3115 and the side wall of the receptacle for illustration purposes only.In the envisioned embodiments, the raised lip 3107 may contact thereceptacle side wall or be spaced apart. Moreover, the frozen liquidcontents may contact the interior of the raised lip 3107. Raised lip3107 may extend only partially along the side of the frozen contents, orthe raised lip may extend to the top of the frozen contents or beyond.The platform 3105 is located between an end layer 3110 of the receptacle3100 and the frozen liquid contents 3115. The platform 3105 is shownspaced apart from end layer 3110 and frozen liquid contents 3115. Insome embodiments, the platform 3105 rests on and is in contact with theend layer 3110, and the frozen liquid contents 3115 is in contact withthe platform 3105 and, optionally, a portion of the end layer 3110. Insome implementations, the raised lip 3107 has an interference fit withthe side wall of the receptacle, while still enabling the platform to bedisplaced from its position near the end layer. In some embodiments, thematerial of the platform 3105 and/or raised lip 3107 is perforated so asto enable any liquid remaining in the space defined by the platform andraised lip to drain.

Any of the receptacle embodiments disclosed herein can, optionally,possess a coating on the inner surface of the mixing chamber formed bythe receptacle to promote ease of release of the frozen liquid contentfrom the inner surface. Considerations for selection of the coatinginclude that the coating must be food safe and not exhibit unacceptablelevels of chemical leaching into the frozen liquid contents duringstorage or into the product during the melting and/or diluting process.Similarly, it must not absorb desirable flavor and aroma compounds oroils from the frozen contents, especially during filling and dispensingoperations when the contents are in liquid form. Other factors includethat the coating must have a favorable coefficient of static friction,porosity measure, and surface roughness measure so as to reduce theforce required to release the frozen liquid contents from the receptaclerelative to an uncoated surface. The coating must maintain the aforesaiddesirable characteristics under the temperature range to which thereceptacle will be exposed (e.g., about −20° F. to about 212° F.) Insome embodiments, the coefficient of static friction of the coatingranges from 0.05 to 0.7. In other embodiments, the coefficient of staticfriction of the coating ranges from 0.3 to 0.4. In other embodiments,the coefficient of static friction of the coating ranges from 0.1 to0.2. In other embodiments, the coefficient of static friction of thecoating ranges from 0.05 to 0.1. In other embodiments, the coefficientof static friction of the coating ranges from 0.08 to 0.3. In otherembodiments, the coefficient of static friction of the coating rangesfrom 0.07 to 0.4. In other embodiments, the coefficient of staticfriction of the coating ranges from 0.1 to 0.7. In some embodiments, thecoating includes one or more of polypropylene,ultra-high-molecular-weight polyethylene, polytetrafluoroethylene,fluorinated ethylene propylene, high-density polyethylene, low-densitypolyethylene and/or mixtures and/or co-polymers of these materials,e.g., polypropylene/polyethylene mixture.

In one embodiment of the invention, a receptacle having any one of thegeometries disclosed herein contains a frozen liquid contents that issized to permit at least 5 mm of space between the frozen liquidcontents and the end layer (bottom) of the receptacle while alsomaintaining at least 5 mm of space between the frozen liquid contentsand the cover layer (top) of the receptacle when the contents aredisplaced from the end layer. In this embodiment, the frozen liquidcontents is further sized to provide a final beverage product at atemperature between about 140° F. and 190° F. when the contents (at 15°F.) are combined with 8 ounces of water at 195° F. Further in thisembodiment, the frozen liquid contents has a concentration level so asto produce a coffee beverage having a final product strength of between1.15 TDS and 1.35 TDS when combined with 8 ounces of water. Stillfurther in this embodiment, the frozen liquid contents (at a temperaturebetween 0° F. and 32° F.) has a hardness level such that force from adispenser and/or known single serve brewer needle (e.g., a hollow needleof about 2.5 mm outer diameter with about a 4 mm long diagonal pointedsection) contacting the contents dislodges it from the inner surface ofthe receptacle rather than embedding in the contents or displacing onlya portion of the contents away from the receptacle's surface. In otherembodiments, the spacing between the frozen liquid contents and the topand bottom of the receptacle is at least 7 mm. In still otherembodiments, the frozen liquid contents has a concentration level so asto produce a coffee beverage having a final product strength of about1.25 TDS when combined with 8 ounces of water.

In some implementations, information about the hardness of the frozenliquid content is included in information gathered by dispenser, e.g.,by way of QR code, RFID, or the other techniques described herein. Thedispenser can use this information to determine whether, when, and whereto puncture the receptacle during the product making process. Forexample, if the dispenser receives information that indicated thehardness of the frozen content is too soft to allow a perforator todislodge the contents from its position in the receptacle, the dispensermay use a secondary heat source to partially melt the contents beforeperforating the receptacle in a location corresponding to the contentsposition opposite the location of perforation. In alternate embodiments,the dispenser has a hardness sensor (e.g., an ultrasonic hardness sensoror other known hardness sensor) that determines the hardness of thefrozen contents.

In addition to the receptacle geometry illustrated in FIG. 16 ,embodiments of the invention include tapered cylindrical receptacleshaving a profile similar to that of receptacle 3200 shown in FIG. 32 andhaving heights ranging from 1.65 inches to 1.80 inches, top innerdiameters (Top ID) ranging from 1.65 inches to 2.00 inches, draft anglesranging from 4 to 6 degrees, and bottom inner diameters (Bottom ID)ranging from 1.30 inches to 1.75 inches (while maintaining the draftangle within the recited range.) In certain embodiments, the heightranges from 1.70 inches to 1.75 inches, the Top ID ranges from 1.70inches to 1.95 inches, the draft angle ranges from 4 to 6 degrees, andthe Bottom ID ranges from 1.35 inches to 1.70 inches (while maintainingthe draft angle within the recited range.) In other embodiments, theheight ranges from 1.65 inches to 1.80 inches, the Top ID ranges from1.75 inches to 1.90 inches, the draft angle ranges from 4 to 6 degrees,and the Bottom ID ranges from 1.40 inches to 1.65 inches (whilemaintaining the draft angle within the recited range.) In still furtherembodiments, the height ranges from 1.65 inches to 1.80 inches, the TopID ranges from 1.80 inches to 1.90 inches, the draft angle ranges from 4to 6 degrees, and the Bottom ID ranges from 1.45 inches to 1.60 inches(while maintaining the draft angle within the recited range.) In oneembodiment, the height is about 1.72 inches, the Top ID is about 1.80inches, the draft angle is about 5 degrees, and the Bottom ID is about1.45 inches. Other ranges of these parameters are within the scope ofthe invention.

Various embodiments of the receptacles described above disclose atapered sidewall. However, other embodiments of receptacles havestraight sidewalls. FIG. 33 shows a cross-sectional view of a receptacle3300 with straight sidewalls 3305 that have a uniform diameter from thetop end to the bottom end of the receptacle. Embodiments having straightsidewalls can incorporate any of the various platform features describedabove. When using such embodiments to create a final food or beverageproduct, a dispenser can at least partially melt the frozen contents3310 in order to provide a flow path from an inlet near the top of thereceptacle, past the frozen contents, to an outlet near the bottom ofthe receptacle.

FIG. 34 shows a cross-sectional side view of a receptacle 3400 with afirst straight sidewall section 3405 and a second straight sidewallsection 3410. First sidewall section 3405 has a smaller diameter thansecond sidewall section 3410 such that when the frozen content 3415 isdisplaced, e.g., by an outlet perforator, a flow path through thereceptacle is created. A platform with a raised lip, such as theembodiment shown in FIG. 31 , can be used with receptacle 3400 to assistin displacing the frozen contents from the first sidewall section 3405as described in more detail above. In such an embodiment, the raised lipof the platform can conform to the lower straight sidewall section 3405,or the raised lip of the platform can be displaced from the innersurface of the sidewall.

The following non-limiting examples are provided for illustrativepurposes only. Other receptacle sizes and other frozen liquid contentsremain within the scope of the invention.

EXAMPLE 1 Coffee Beverage

In one embodiment of the invention, a filterless single chamber mixingreceptacle contains a frozen liquid contents. The receptacle has aprofile similar to that shown in FIG. 32 and has a height of about 1.72inches, a Top ID of about 1.80 inches, a draft angle of about 5 degrees,and a Bottom ID of about 1.45 inches. The receptacle is sealed on topwith a perforable layer and the end layer is perforable (e.g., by adispenser/brewer needle, such as, but not limited to, the needlesdescribed above). The frozen liquid contents is a concentrated coffeeextract that is in contact with substantially the entire end layer and aportion of the sidewalls.

In order to produce a final coffee beverage product having a TDS ofbetween 1.15% and about 1.35% TDS (with an optional target of 1.25%TDS), the frozen liquid contents, at 15° F., is melted and diluted witheight ounces of water at 195° F. Table 1 shows several alternativeimplementations of the frozen liquid contents of this embodiment as wellas the impact on various parameters of varying the amount of frozenliquid contents and degree of concentration of the contents.

TABLE 1 Contents Empty Space Empty Space Final Contents Contents HeightAbove Above In Receptacle Contents Contents Product Volume Weight EndLayer Contents Volume TDS Brix Temperature (in³) (oz) (in) (in) (%) (%)(°Bx) (° F.) 0.3 0.18 0.13 1.57 91 57 67 188 0.5 0.30 0.25 1.45 85 35 41183 0.7 0.42 0.37 1.33 79 25 29 178 0.9 0.54 0.49 1.21 73 20 24 175 1.50.90 0.81 0.89 56 12 14 162 2.0 1.20 1.07 0.63 41 10 12 153 2.9 1.741.49 0.21 14 7 8 137

As shown in Table 1, in order to keep the coffee beverage temperatureabove 140° F. (e.g., to accommodate the addition of milk or cream whilemaintaining a beverage temperature above 120° F.), the frozen liquidcontents weight is between about 0.15 and about 1.2 ounces at a degreeof concentration of between about 60% TDS and about 8% TDS (wheresmaller contents require higher concentration). When included in thereceptacle, the length of the empty space above the frozen liquidcontents and below the top layer (i.e., headspace) is between about 0.6and about 1.6 inches, which yields an empty space volume of betweenabout 41% and about 91%.

Applicants have discovered that maintaining a frozen liquid contentsheight of about 0.5 inches or less from the end layer of the receptacleincreases the ease of release of the contents from the end layer. Thusthe contents can be further restricted to a height of between about 0.5and about 0.1 inches, thereby having a corresponding degree ofconcentration of between about 60% and about 20% TDS. Doing so increasesthe headspace and empty volume relative to the previous example, whichis expected to improve melting and mixing given the increased ratio ofwater in the mixing chamber relative to the frozen liquid contents.

It may be desired to limit the range of degree of concentration of thefrozen liquid contents to no more than 35% TDS. For example, to conserveenergy, as creating relatively frozen liquid contents with higherdegrees of concentration consume more energy to produce than those withrelatively lower degrees of concentration and may require secondaryprocessing such as by reverse osmosis removal of water during theextraction process. In such a case, the frozen liquid contents possessesa weight of about 0.30 to about 0.5 ounces, leaving a headspace ofbetween about 1.2 and about 1.45 inches with an empty volume of about73% to about 85%.

EXAMPLE 2 Espresso Beverage

In another embodiment of the invention, a filterless single chambermixing receptacle contains a frozen liquid contents. The receptacle hasa profile and dimensions that are the same as the one described inExample 1. In this example, the frozen liquid contents is also aconcentrated coffee extract that is in contact with substantially theentire end layer and a portion of the sidewalls.

In order to produce a final espresso beverage product having a TDS ofbetween about 9.15% and about 9.35% TDS (with an optional target ofabout 9.25% TDS), the frozen liquid contents, at 15° F., is melted anddiluted with sufficient water at 195° F. to yield a dispensed volume offour ounces (sometimes described as a double espresso). Table 2 showsseveral alternative implementations of the frozen liquid contents ofthis embodiment as well as the impact on various parameters of varyingthe amount of frozen liquid contents and degree of concentration of thecontents.

TABLE 2 Contents Empty Space Empty Space Final Contents Contents HeightAbove Above In Receptacle Contents Contents Product Volume Weight EndLayer Contents Volume TDS Brix Temperature (in³) (oz) (in) (in) (%) (%)(°Bx) (° F.) 1.0 0.64 0.54 1.16 70 58 68 145 1.1 0.70 0.60 1.10 67 53 62140 1.2 0.76 0.65 1.05 64 48 56 134 1.3 0.83 0.71 0.99 61 45 53 128

Similar results can be obtained by using other receptacle designsdisclosed herein with the various implementations of the frozen liquidcontents set forth in the Tables 1 and 2 and as described in theaccompanying descriptions above. Thus, the scope of the invention is notlimited to the use of the specific implementations of frozen liquidcontents in the receptacles with the profile as shown in FIG. 32 .

As discussed throughout the description, embodiments of the inventionprovide many benefits. For example, because the receptacles are singlechamber mixing vessels, the receptacles do not retain filter material,spent coffee grinds, used tea leaves, or other materials that preventthe receptacles from being easily recycled as a single stream. Moreover,by providing a frozen liquid contents that is created by an extractionprocess, the byproducts, such as coffee grinds, are maintained at acentral facility, which can be more readily recycled or reused (such asa source of biomass energy and/or sustainable soil nutrients.) Furtherstill, a much greater variety of final products can be supported throughthe use of frozen liquid contents, as described in more detail above.Thus, it is understood that frozen liquid contents having higher orlower TDS values than those given in the illustrative examples above arewithin the scope of the invention. Further examples include TDS valuesbetween 0.5 TDS and 68% TDS, including ranges of 1% TDS to 68% TDS, 2%TDS to 68% TDS, 3% TDS to 68% TDS, 4% TDS to 68% TDS, and 5% TDS to 68%TDS.

Also as discussed through the description, embodiments of the inventionprovide for automated systems and techniques for producing a widevariety of liquid food and beverage products based on information aboutthe source materials (e.g., frozen liquid contents, dilution liquids,etc.) as well as information about the final product itself (e.g.,desired volume, temperature, etc.). Further illustrative embodiments ofsystems and techniques for producing such products follow below. Aspectsof these embodiments can be combined with any of the other aspects setforth above and remain within the scope of the invention.

Referring to FIGS. 35A, 35B, 36A and 36B, two different embodiments ofportions of a dispenser for creating liquid food and beverage productsare shown. As noted above, portions of the dispenser include equipment,sensors, controls, etc. needed to store, optionally heat, and deliverliquid to a dispenser head (an inlet to supply liquid into a receptacle)as metered amounts of liquid in a set periods of time depending on theproduct being dispensed. In the following examples, water is used as thedilution liquid. A metered amount of water within a set temperaturerange is passed into the dispenser head in either continuous flow,pulsed or separated into volumes of water between air pulses. At theconclusion of the dispensing, air is blown through the lines to thedispenser head to purge the air/water lines and deal with residualwater, thereby reducing sanitation issues. FIGS. 35A and 35B representone embodiment in which separate fluid pumps 3551 and 3552, and separateair pumps 3521 and 3522, are used to route the dilution fluid (e.g.,water) from the primary storage reservoir 3510 either through the heater3530 or directly to the dispenser head via transfer point A 3570. FIGS.36A and 36B represent a different embodiment in which only one pumpfluid pump 3650 and one air pump 3620 are used with diverting valves3681 and 3682 employed to control whether the fluids go through theheater 3630 or directly to the transfer point 3670.

FIG. 35A illustrates the case in which fluid pump 3551 and air pump 3521are active, taking fluid from reservoir 3510 and pumping it throughheater 3530 such that the fluid arrives at the transfer point A at sometemperature greater than that in the reservoir. Air pump 3521, whenactivated, purges the heater 3530 and the air lines leading to point A3570.

FIG. 35B illustrates the case in which fluid pump 3552 and air pump 3522are active, taking fluid from reservoir 3510 and delivering it to pointA 3570 at the same temperature as while stored in the reservoir 3510. Insome embodiments it is possible to combine the operations shown in FIGS.35A and 35B at different times during the product generation/dispensecycle such that the final beverage temperature can be tailored to meetthe users expectation. As an example, for a cold beverage selection suchas orange juice, it may be desirable to dispense a small amount of hotwater at the beginning of the cycle to slightly warm the frozen contentsin the receptacle and create a clear exit path for fluids to thereceptacle exit. Then, to avoid producing an overly warm beverage, thebalance of the dispense cycle is conducted using ambient temperaturewater directly from the reservoir with the expectation that this waterwill be somewhat cooled by the process of melting the remaining frozencontents in the receptacle. The air pumps 3521 and 3522 can be activatedduring dispense of water to increase cavitation/turbulence in thereceptacle. Once the dispense cycle is complete, at least through thepoint that the consumer removes the beverage from the dispenser, a finalportion of hot water may be passed through the system to clean variouscomponents in the dispenser head. This cleaning purge of hot water couldthen be followed by short air purges from both air pumps 3521 and 3522to clear the lines. In some embodiments, this cleaning water is directedto a drip tray where it either evaporates or is periodically emptied bythe user.

FIG. 36A illustrates a case where diverting valve 3682 is configured todivert fluid from the reservoir 3610 to heater 3630 and on to transferpoint A, item 3670. Meanwhile, diverting valve 3681 is also configuredto send air to heater 3630.

FIG. 36B illustrates a case where diverting valve 3682 is configured todivert fluid from the reservoir 3610 directly to transfer point A 3670.Meanwhile, diverting valve 3681 is also configured to send air todirectly to transfer point A 3670.

For some embodiments, reservoir 3510 contains an unheated fluid that maybe at ambient/room temperature or may contain a chilled fluid, even onesuch as water containing ice cubes. For some embodiments heater 3530 isan electrically heated vessel similar to those well known in the art forquickly heating small volumes of fluids. Heater 3530 may or may not bepressure rated and suitable for creating steam instead of hot liquidwater. In some implementations, reservoir 3510 is insulated from heater3530, e.g., to prevent the heater 3530 from heating the liquid inreservoir 3510. Although not shown, certain implementations of thedispensers include a filter disposed in the flow path of liquid exitingthe reservoir. Similarly, a water conditioner, e.g., a water softeningdevice, can be included in the flow path of liquid exiting thereservoir. In some embodiments, the reservoir is removable.

For some embodiments, pumps 3550, 3551 and 3552 are constantdisplacement pumps, e.g., piston pumps or peristaltic pumps or even duallobe pumps. For some embodiments, pumps 3550, 3551 and 3552 are combinedwith a flow sensor for measuring and controlling the rate of flow aswell as the absolute volume of the flow. Any of these pumps can be anaxial or centrifugal pump that does not pump a constant volume over timeor per revolution, but instead are controlled in a closed-loop processto deliver a measured amount of fluid as measured by the flow sensor. Insome embodiments valves 3681 and 3682 are 3-way ball valves well knownin the art. In some embodiments valves 3681 and 3682 are multi-portsolenoid valves also well known in the art. In some embodiments valves3681 and 3682 are motorized compression valves. In some embodimentspressures sensors 3580 and 3582, temperature sensors 3590 and strokesensors for some pumps 3595 and 3597 are used to provide systemperformance information back to the controller for use in variousfeedback algorithms to keep the system operating as required to dispensea fluid in the right volume and at a preferred temperature to yield afinal beverage that satisfies the user's preferences. In someembodiments the pressure sensor information is used to adjust the strokeof the pumps to fine tune the dispensed liquid for either system, hot orcold.

One beneficial aspect of embodiments of the dispenser is the system forsupplying secondary (non-diluting) thermal energy to the receptacle andits frozen contents to help manage the final average temperature of thedispensed food or beverage product. As described herein, techniques foradding thermal energy can include direct conduction through the sidewallof the receptacle from an electrically heated or water heated collar,impingement of hot gases, air, or steam against the outside of thereceptacle, use of various forms of electromagnetic energy that can heateither the receptacle or directly heat the frozen contents. Someexamples of the latter include infrared irradiation, RF heating,microwave heating, and the like. FIGS. 37A-39B show three illustrativeembodiments of portions of a dispenser system, illustrating how thissecondary (non-diluting) metered thermal energy can be combined with (a)melting/diluting fluids delivered through transfer point A 3570described above, (b) different forms of agitation to help expediteliquefaction of the frozen contents, and (c) different strategies forholding and perforating the receptacles to allow for venting, fluidaddition, draining, and heating/melting using heatedneedles/perforators. To be clear, the characterization as these sourcesof heat as “secondary” does not require that the heat be applied secondin time to another heat source or that the secondary heat sourcesupplies less heat than some other source of heat. The term“non-diluting” describes a heat source that does not supply a dilutionliquid to the interior of the receptacle as a way of heating the frozencontents.

FIGS. 37A-E illustrates one embodiment, among many possible, wherein asystem for impinging hot air against the receptacle provides thesecondary (non-diluting) thermal energy. In this exemplary system, avariety of different technologies are combined to create the overallsystem used for melting, diluting and dispensing the frozen contentswithin the receptacle into a beverage of desirable potency and volumesatisfactory to the user. One skilled in the art will recognize that thevarious technologies illustrated in FIGS. 37A-E and throughout the otherillustrations that follow can be combined in many different variationsand combinations to realize the same objective. In some embodiments, thereceptacle is first scanned to determine the nature of its contentsusing some type of optical sensor 3705. In some embodiments, asuccessful scan (e.g., the system recognizes the receptacle asacceptable via the scanned information) causes drawer 3703 to open sothe receptacle cavity 3706 can be filled with the user's receptacle ofchoice 3704. In some embodiments, the user initiates the continuation ofthe dispense cycle by pushing a button, reengaging the drawer with thedispenser housing, or some other step to positively indicate a decisionto proceed. In certain implementations, the dispenser has a lock thatengages after the drawer 3703 is closed so that the drawer 3703 cannotbe reopened until the dispenser completes the dispense cycle orotherwise unlocks the drawer.

In some embodiments, upon this signal, drawer 3703, supported by somestructural elements 3710 in the dispenser slides closed. In someembodiments a mechanism such as plate 3707 is driven down onto the topof the receptacle to reinforce the receptacle lid against leakage and topuncture the lid with a liquid dispensing needle. In some embodiments,either before the start of agitation and addition of a diluting liquidor simultaneously with these steps, some amount of thermal energy isadded to the receptacle 3706 to warm or partially or fully melt thefrozen contents. In some embodiments this thermal energy is supplied byair blown by a fan 3701 through a duct 3702 and over a heater 3700. Insome embodiments, the heater 3700 is electrically heated. In someembodiments the heater 3700 is a water-to-air heat exchanger using hotwater from the heater tank (item 3530 in FIG. 35A) or some secondaryheater (not shown). In some embodiments the heater 3700 is an element ofa thermoelectric device that can be used to cool the receptacle or thecavity at some point later in the cycle or after the cycle to removeexcess heat (e.g., a Peltier cooler and/or heater).

The effectiveness of hot air heating will be greatly enhanced if thesides of the receptacle are directly impinged by the hot air.Accordingly, in some embodiments, cavity 3706 is an open or porousstructure which allows much or all of the sidewalls of receptacle 3704to be directly contacted by the impinging air. For example, the cavitymay consist solely of a collar which captures the uppermost portions ofthe receptacle sidewalls or stacking ring and does not extend downwardin any way to shield the receptacle from the flow of air. In someembodiments, as noted above, either in conjunction with the addition ofsecondary thermal energy or later in the cycle in conjunction with theaddition of a dilution fluid (e.g., water), some level of agitation ofthe receptacle and the frozen contents inside is initiated to increasethe number of collisions between the dilution liquid and the frozencontents, break up any stagnant layers of diluting liquid, etc. tohasten the liquefaction of the frozen contents. In some embodiments,this agitation is caused by motor 3708. In some embodiments theagitation is rotary 3712. In some embodiments the rotation isreciprocating with either large motions (e.g., 90-120° in one directionbefore reversal and then repeated) or small motions (e.g., vibratory or<<90°). In alterative implementations, a solenoid is used to impartagitation.

In some embodiments, in conjunction with the agitation or beforeagitation begins, a melting/diluting liquid is added to the receptacle.This liquid is delivered from the portions of the dispenser describedabove via transition point A 3570. In some embodiments, thismelting/diluting liquid is delivered directly from the water reservoirand arrives at approximately its original temperature in the reservoir.In some embodiments, this melting/diluting liquid is passed through aheater tank en route to transition point A. In some embodiments, inconjunction with the addition of melting/diluting liquids, the bottom ofthe receptacle 3704 is punctured with a second needle or perforator 3709so the melted liquids can drain into the user's cup 3714. In someembodiments, once the dispense cycle is finished and almost all of themelting/diluting liquid has drained from the receptacle, having fullymelted the frozen contents and washed the inside of the receptacleclean, drawer 3703 reopens and receptacle 3704 can be removed anddiscarded 3716. Optionally, before the draw reopens, the system can coolthe receptacle by forcing ambient, or cooled, air through the duct 3702into contact with the receptacle 3705.

As noted elsewhere in this description, agitation of the frozen liquidcontents is an efficient means for increasing its rate of liquefaction.Regardless of the exact mechanism from a fluid dynamics perspective,whether that be breaking up boundary layers between solids and theheating liquid, increasing relative velocity between the two, theincreased incidence of physical contact between solids, or even thesmall amount of kinetic energy converted to heat, the observed resultsare clear. Melting of the frozen contents occurs much faster withagitation than without.

In some embodiments this agitation takes the form of vibration or verysmall amplitude oscillatory movement of the contents. Systems andtechniques for mechanically inducing vibration are well known in theart, including magnetic excitation of materials, supplying a varyingelectrical signal to piezo-electric components, and use of an off-centerweighted rotating discs.

While vibratory-level oscillation is more effective than no agitation,the efficiency of liquefaction increases with the amplitude and energylevel of the interaction between solid (frozen or partially frozen)components and the melting/diluting liquid. In some embodiments, thislarger amplitude agitation is induced by mechanical or fluidic forces.Mechanical forces include imparting relatively larger angle rotations ofthe cavity and/or the receptacle, typically motor driven, either througha direct axial connection or through a belt, gear or friction drivearrangement. Asymmetric oscillation, wherein the clockwise andcounterclockwise amplitudes of rotation about a neutral point areunequal over short periods of time has proven especially efficient as itprevents the creation of regular patterns, standing waves, etc. with aresulting increase in the local chaotic nature of the fluid.Multi-rotation motion, i.e., spinning complete revolutions for severalseconds in one direction and then the other is also useful. This motioncreates less chaotic movement of the fluid, but may introduceopportunities for preferentially directing the centrifugally drivenfluids.

In some embodiments the driving motors for mechanical agitation are DCdriven motors that are driven by the magnitude and polarity of the DCvoltage fed to them by the controller, sometimes through a special motorpower supply optimized for the particular motor. In some embodiments thedriving motors are stepper or servo motors that can be more preciselyprogrammed to execute specific patterns of motion and can be used, ifkeying features are incorporated into a receptacle and cavity, to returnthe keyed feature to a specific location for loading, unloading,scanning, and the like.

In some embodiments, as described above, melting/diluting fluids areinjected into the receptacle tangentially once a small liquid bearinginterface has been melted between receptacle inner surface and frozencontents. This liquid is injected for the purpose of causing the frozencontents to spin inside the receptacle for faster liquefaction of thefrozen contents. In some instances, the volume of the melting/dilutingfluid that can be added to the receptacle is limited and unavailable tokeep the frozen contents spinning long enough to achieve the desiredlevel of melting. In some embodiments, an alternative technique to causethe frozen contents to spin is the injection of compressed air or othergas through the needle such that this gas impinges upon the frozencontents near its outer diametric edge in a tangential direction. Insome embodiments this gas is developed/compressed and stored in anappropriate vessel inside or proximate to the dispenser prior to when itis needed using mechanical or chemical means as are well known in theart, e.g., mechanical pumps or chemical reactions known to produce agas.

In some embodiments a mechanical or chemical means of producing a gascontinuously at the required pressure is used to supply the injectionneedle. For example, a larger pump could be used. In some embodimentsthe flow of this gas to the injection needle is timed and controlled bythe dispenser system controller and coordinated with the flow ofmelting/diluting liquid through the same or a separate needle, before orafter the injection of gas, or interspersed with the gas. For example, asmall amount of liquid could be injected, followed by a burst orprolonged stream of gas, followed by more liquid, and so on, until theplanned cycle is complete.

Fluid-based techniques of inducing agitation take advantage of the lowfriction coefficient that exists between frozen contents within thereceptacle and the receptacle walls once a thin film of liquid has beenmelted between the two surfaces creating a liquid bearing interface.Under this circumstance, it is possible to use steady or pulsed flowsfrom the injection needle, directed tangentially near the sidewall ofthe receptacle, to cause the frozen contents to begin to spin. Fluidinduced agitation is particularly attractive in its reduction ofmechanical complexity and cost within the dispenser. These benefits mustbe weighed against the loss of process control flexibility and limitsimposed by the amount of melting/diluting fluids that may be availablefor some types of beverage or food receptacles. In some embodiments along needle passes fully through the receptacle and the frozen contentsand remains in place as a drip guide for the contents or the dilutionfluids exiting the receptacle to the user's cup or dispenseware. In someembodiments this needle is shaped like a bayonet and is electricallyheated to facilitate its passage through the frozen contents. Once theneedle is in place, extending through the lid and closed end of thereceptacle, a second needle is introduced into the receptacle and beginsto inject a fluid tangential to the diametric curvature of the sidewallsof the receptacle to induce the frozen contents to spin within thestationary receptacle utilizing the thawed contents as a lubricant tospinning. In some embodiments the stationary receptacle is externallyheated before and/or during the puncturing with the bayonet andintroduction of fluids as a means for increasing the entropy of thesystem and facilitating liquefaction. The contents, as it melts, flowspast the bayonet and drips off its lowermost tip. In some embodimentsthe last of the frozen contents melts before all of the diluting liquidhas been injected, allowing a clean cup to be removed from the dispenseronce the needle/bayonet is withdrawn.

FIGS. 38A-E illustrates another system and technique by which thereceptacle can be captured in the dispenser and the frozen contentsmelted, diluted and dispensed. Because many of the features of thisalternative system are similar to what was just described in connectionwith FIGS. 37A-E, further explanation will focus on the alternativetechnique for adding secondary (non-diluting) thermal energy. In someembodiments, as shown in FIG. 38 , a receptacle is scanned (FIG. 38A)and inserted into a chamber 3801. The receptacle 3804 is held by aclosely matched conical surface 3806 of the chamber. As an analogy whichwill be readily understood by one knowledgeable in the art, the matingtapered sidewall surfaces of the receptacle and the heater are ideallyin contact much the same way that a machine tool and a holding chuck,both machined with matching Morse Tapers, are in intimate contact. Insome embodiments the external matching surface 3806 is a part of anelectrical resistance heater 3800 which may be controllably heated to adesired temperature, e.g., 195-205° F. (below the boiling point of thefrozen contents once melted).

As with the previous example involving hot air, in some embodiments thisheater 3800 can be activated for a period of time calculated by thedispenser controller using knowledge about the frozen contents gainedfrom the initial scan and various on-board sensors. This period of timemay be designed to warm, partially melt or fully melt the frozencontents depending on the desired final dispensed beverage/foodtemperature and planned volume. For this heating process, especially ifthe intent is to partially melt the frozen contents, knowledge of thefreeze/thaw temperature of the frozen contents is needed. Thisinformation, which can be gathered from scanning the receptacle 3804, asdescribed elsewhere herein, is used within a temperature feedback loopcontrol. The nominal freeze/thaw point may also be estimated based onknowledge of the contents of the frozen contents (% water, % sugar, %fat, % protein, etc.). As described above in connection with FIGS.37A-E, the receptacle can be agitated before, during, or after heating,and the liquid food or beverage product is dispensed (FIG. 38D). FIG.38E shows the removal of the empty and cleaned receptacle 3804. Althoughnot shown in the figures, the close-fitting relationship between thereceptacle and the inner surface of the chamber could be achieved bysubmersing the receptacle in a heated liquid bath.

FIG. 39A illustrates the use of a radio frequency (RF) coil to providethe source of secondary thermal heat to the receptacle using otherwise asimilar process as described for the embodiments shown in FIGS. 37A-Eand 38A-E. In some embodiments, a power supply 3921 sends a highfrequency electrical current to coil 3920. The oscillating electricalfield is known to interact with ice, but with substantial dielectriclosses that convert to heat. Oscillation frequencies in the range of 3MHz have been shown to be particularly efficient in this heatingprocess. As in the other illustrations presented herein, this secondaryheat is managed by a micro-controller within the dispenser to coordinatethe timing, duration and power with other events throughout themelting/diluting/dispensing cycle including agitation, addition offluids inside the receptacle, and the schedule of different needlepunctures.

FIG. 39B illustrates the use of electromagnetic energy as a secondaryheat source to heat the frozen contents. In one implementation,microwave energy is used. One knowledgeable in the art will recognizethat the magnetron used to supply high frequency electromagnetic energycan be designed to develop frequencies from the low megahertz range tothe gigahertz range. In an illustrative example, a power supply 3940feeds a magnetron (alternating electrical frequency generator) 3941 todeliver a beam of energy to the receptacle. In some operating scenarios,the electromagnetic heating cycle is started before the receptacle ispunctured by one or more needles. In other scenarios, theelectromagnetic heating cycle is started after the receptacle ispunctured by one or more needles. In some use cases, the initialpuncture of the receptacle is managed to simply provide a small ventsuch that any vapor or steam created by the secondary heating process isable to escape the receptacle without any significant pressure buildup.In some embodiments, the receptacle is held within the dispenser cavitywith its axis of symmetry oriented vertically during heating, dilutionand agitation. In this instance, the electromagnetic energy is directedinto the receptacle through the sidewalls of the receptacle. In someembodiments, the receptacle is held within the dispenser cavity with itsaxis of symmetry oriented horizontally during heating, dilution andagitation. In this instance, the electromagnetic energy is directed intothe receptacle through the lid or closed end of the receptacle. In someimplementations, in which the receptacle material is aluminum, someother metal or otherwise conductive, a “window” in the lid or the closedend of the receptacle (depending on which side faces the emitter) isproduced from a material that is more transparent to the frequency ofthe energy being used. In some embodiments this window is a circular orrectangular patch (to match the shape of the emitter or receptacle) thatis thermosealed over a hole in the closed end of the receptacle or ahole in the aluminum lid. In some embodiments the entrance and exitneedles are shielded by ground planes.

FIG. 54 illustrates a portion of a dispenser 4700 with a chamber 4710that holds a receptacle 4715 in a horizontal position rather than avertical position as shown in other embodiments. A dilution liquid inlet4720 perforates the top of the receptacle (which may be covered in ametallic foil) at a position above the location at which a productoutlet 4725 is formed in the top of the receptacle. In oneimplementation (shown by arrows), the chamber provides agitation aboutcentral axis 4730 of the chamber 4710. In an alternate implementation,the dispenser provides agitation along the central axis 4730. Tubingjoining the dilution liquid inlet 4720 to transfer point A 3570 and/ortubing joining product outlet 4725 to the ultimate product outlet isflexible to accommodate motion imparted to the receptacle.

In one embodiment of the invention, a radio frequency (RF) dielectricheating system provides secondary heat (i.e., non-diluting heat) to thereceptacle and/or the frozen liquid contents in the receptacle. In oneimplementation, the process use a high frequency electrical signal,e.g., in the range of 6-42 MHz, to cause rapid vibration of the watermolecules in the compound. It is believed that the heating occursthroughout the entire volume of the contents of the receptaclesimultaneously rather than being an outside-in process. Thus, RFdielectric heating, in some cases is faster at heating liquids thanother known techniques, such as contact or convective heating.

FIG. 40 illustrates a cross-section view of a system 4000 for heatingfrozen liquid contents of a receptacle using RF dielectric heating. FIG.40 shows a receptacle 4003 housing and a lid 4002 over the housing; thereceptacle holds a frozen liquid contents 4004. The receptacle housing4003 is metallic and conductive while the lid 4002 material is anon-conductive plastic, such as polypropylene. An RF power source 4006is electrically connected to an upper contact 4001 and lower contact4005. Lower contact 4005 is also in electrical contact with metallicreceptacle housing 4003. The application of an alternating voltagebetween 4001 and 4005 creates an alternating electrical field whichpasses through the frozen contents 4004. Optionally, upper contact 4001is sized to achieve fairly uniform field lines/gradients through thefrozen liquid contents so as to reduce hot spots. In one embodiment, thediameter of the upper contact 4001 is chosen to create an approximatelyequal gap between the edges of the upper contact and the side walls ofthe receptacle housing 4003.

In another implementation, again referring to FIG. 40 , both thereceptacle housing 4003 and lid 4002 are non-conductive plasticmaterials. Optionally, upper contact 4001 and lower contact 4005 areidentically shaped and sized with the contact being flat (i.e., withoutun-turned sidewalls as depicted in FIG. 40 ), and the diameter of bothwould extend 1-2 mm beyond the edge of the receptacle lid 4002.

Referring to FIG. 49 , one of the known problems with RF dielectricheating techniques involving both water and ice is the non-uniformheating nature of the process. When water molecules are captured withina crystalline structure, as is the case with ice, they are no longerfree to follow the rapidly changing electrical orientation of the fieldbetween the two electrical contacts or that are created by impingingmicrowave energy. As shown in the graph for temperatures below 0° C.,this results in a relatively low dielectric loss factor. Once the icemelts, however, the loss factor rises very quickly, and the meltedwater, existing in small localized pockets typically formed with RF ormicrowave heating within the overall ice structure, heats rapidly. Thisnon-uniform heating can even result in localized boiling and steamcreation if temperatures are not allowed to equilibrate.

Several methods have been developed to deal with this well-knownproblem. One known technique is to pulse the application of power inon/off cycles. Doing so allows some of the heat in the small pockets ofwater to pass into the surrounding ice and thereby progressively enlargethe volume of each pocket until the entire ice structure is converted towater. While this technique of heating is less efficient than what ispossible with a product that is initially all liquid (where RF ormicrowave power can be applied continuously), it is still considerablyfaster than can be achieved with more conventional conduction heatingmethods. This is especially true when the temperature of an externalheat source is necessarily limited to prevent damage to the heatedliquid near the outside of the bulk frozen contents. For example, as inheating frozen orange juice, where excess heat can affect the structureof complex sugars and degrade taste.

FIG. 41 is an isometric view of a cavity cover 4100 including two fluiddelivery needles 4102, 4103 and a central electrode 4105 for ohmicheating. Ohmic heating can serve as an alternative to dielectric heatingfor heating the frozen liquid contents, and can still operate on avolumetric basis. This process requires frozen contents that conductselectricity, but still offers some resistance to electron flow. In oneimplementation, electric current is introduced at one contact, causingthe electricity to flow through the frozen liquid contents or meltedliquid, to a second contact. In this end view of assembly 4100, thecavity sealing plate 4101, made from a non-conducting material such asan injection molded plastic, locates and holds needles or penetrators4102, 4103 for flowing a dilution liquid and/or a melted product. Theplate 4101 also locates and holds the electrode 4105, which includes aninsulating sheath 4104.

In some embodiments, the electrode assembly, the combination of sheath4104 and electrode 4105, is fixed in place with one end protrudingbeyond the back of plate 4101. Optionally, this assembly is springloaded, allowing the electrical contact to progressively move furtherinto the receptacle as portions of the frozen contents melt so as tomaintain contact with the frozen core. In some embodiments, insulator4104 is a ceramic material, for example aluminum oxide, that hasfavorable strength and relatively high electrical resistivity.

FIG. 42 is a cross-section view of a first implementation of the ohmicheating system 4100 of FIG. 41 . The single electrical probe 4105 isshown slightly embedded in frozen contents 4004. Using an electricalinsulator 4104 to cover conductor 4105 allows the use of a metallic lid,such as aluminum foil, to close the receptacle during packaging. Duringthe secondary heating phase of a process for creating a liquid food orbeverage, described in more detail above, electricity flows fromelectrical contact 4105 into the frozen contents 4004 to a conductive(e.g., aluminum) receptacle housing 4003, and finally to electricalcontact 4107. Electrical power is supplied by a source 4106 that, insome embodiments, is an alternating current (AC) supply. Using an ACpower supply is thought to avoid problems with electrolysis that mayoccur at one or both electrical contacts with the use of a directcurrent (DC) power supply.

FIG. 43 is a cross-section view of a second implementation of the ohmicheating system 4100 of FIG. 41 . In the embodiment shown, electricalcontact 4108 is equipped with one or more small penetrating cones orsimilar shape bodies 4109 integral to the contact. These conicalprotrusions 4109 pierce the bottom of the receptacle housing 4003 tomake a direct electrical connection between the frozen contents 4004 andthe electrical contact 4108. This can be advantageous when thereceptacle housing 4003 is non-metallic or the inside surface of thereceptacle is covered with a non-conductive coating, e.g., a thin layerof polypropylene used to coat an aluminum receptacle to enhance foodsafety, eliminate chemical reactions between the aluminum and the food,and/or to provide a welding surface for the heat sealed lid.

FIG. 44 shows an isometric view of a cavity cover 4200, including twofluid delivery needles 4102, 4103 and two electrodes 4105, 4111 forohmic heating. Meanwhile, FIG. 45 is a cross-section view of the ohmicheating system 4200 of FIG. 44 . System 4200 uses two electricalcontacts 4105, 4111 located and held by end plate 4201. A completeelectrical path includes the two electrical contacts and the frozencontents, without the need for a metallic receptacle housing 4003. Thus,this implementation will work equally well with conductive (metallic)and non-conductive (plastic) receptacle housings 4003. As describedabove, these electrode assemblies can be fixed or spring loaded. As withthe other secondary heating sources set forth above, the implementationsof ohmic heating can supply heat before, during, or after the additionof dilution fluids and/or with and without agitation. The concept can beeasily adapted to any of the dispenser configurations set forth in moredetail above, including, for example, the dispensers with verticallyaligned cavities.

In some embodiments, power supply 4106 has circuitry to detect animpending breakdown of a dielectric and limit the current supplyaccordingly to prevent electrical arcing using known methods.

FIGS. 51 and 52 are isometric views of two spiral coiled electrodes 4500for use with embodiments of the ohmic heating systems described herein.As described above, ohmic heating operates based on the resistivity of afrozen solid or liquid to cause heating when an electric current ispassed through the material. Localized heating at the point of currentintroduction can lead to inefficiencies or ineffective heating. Moreuniform heating occurs when the electrical contact surfaces at theelectrode/food interface are larger rather than smaller. In oneembodiment, electrical contact surfaces (electrodes) are included in thereceptacle prior to forming a frozen liquid content in the receptacle toincrease the surface area available for electrical contact beyond whatis achieved with needle-like electrodes.

FIG. 51 shows two spiral coiled shapes 4501, 4502 that act as theelectrodes. In some embodiments, these coiled electrodes are stainlesssteel foil material attached to contact surfaces 4505 and 4506,respectively. FIG. 52 shows the same spiral coils 4501, 4502 and contactsurfaces 4505, 4506 without the cup body 4515 for clarity. An insulatingframe 4510 holds the coils in place. Contact surfaces 4505, 4506 aredisposed in the receptacle so as to make contact with electrodes in adispenser system when inserted into the receptacle (e.g., as shown anddescribed for the embodiment of FIG. 45 ). FIG. 52 shows anotherembodiment of two electrodes 4601, 4602 formed as an open rectangularbody.

FIG. 46 is an isometric view of a heating system 4300 that usesmicrowave energy to heat frozen liquid contents in a receptacle. Heatingsystem 4300 has a chamber 4310 with a chamber lid 4312 and a chamberbody 4314, joined by a hinge 4316. The chamber body 4314 has areceptacle opening 4318 sized to receive a receptacle holding frozenliquid contents. FIG. 46 shows the chamber 4310 open, while FIG. 47shows the chamber 4310 closed. Meanwhile, FIG. 48 shows a cross-sectionview of the heating system 4300 of FIGS. 46 and 47 .

Heating system 4300 is yet another form of a secondary heating systemthat can be used with the several embodiments set forth herein. Heatingsystem 4300 uses microwave energy, a source of high frequency electricalenergy, which is transmitted to a receptacle when held in the chamber4310. Some implementations of the heating system 4300 use a magnetron asthe source of microwave energy. This magnetron can operate at, e.g.,approximately 2.45 Gigahertz. Other embodiments use a magnetron thatoperates at 5.8 Gigahertz and delivering 700 Watts or more. Magnetronsoperating at still higher frequencies are available and have relativelylower power levels. At present, magnetrons operating at 5.8 Gigahertzand higher are relatively more expensive than their 2.45 Gigahertzcounterparts. However, use of magnetrons with relatively higherfrequencies is within the scope of the invention and can offer benefits,as described below.

At the lower end of the microwave frequency spectrum, e.g., 2.45 GHz,transmission of the created waveforms is possible both by waveguide andby coaxial cable. Use of a coaxial cable beyond 3 GHz can impractical,at least at relatively higher power levels. It is believed that the useof coaxial cable for energy delivery is suitable at power levels of 700Watts or less. Thus, in certain implementations, a coaxial cable is usedfor energy delivery to the receptacle when held in the chamber 4310.Such an implementation would benefit in terms of cost, flexibility andrequired volume within the dispenser for routing the RF energy signal.Adaptation to a coaxial cable transmission design could be accomplished,for example, in accordance with the techniques set forth in U.S. Pat.No. 5,216,327, incorporated by reference herein.

The disclosed techniques address challenges associated with usingmicrowave energy to thaw and heat frozen contents. For example, asexplained above, without implementing proper safeguards, portions of thefrozen content volume that first transition from ice to liquid canoverheat. Also as discussed above, techniques such as pulsed heatingthat work for RF dielectric heating will work for heating with microwaveenergy. Another challenge associated with using microwave energy insideof a conductive receptacle is the fact that the electrical field at thesurface of the conductive material will always be essentially zero. Thisnull condition sets up a zone of no heating that extends into thereceptacle for about a quarter of the wavelength from the receptaclewall. If the receptacle is large enough, with respect to the wavelength,e.g., more than several wavelengths in depth, heating can occur in theremainder of the frozen contents. While this approach may still producehot and cold spots if a standing wave is created, melting will occur.These hot and cold spots are dealt with in microwave ovens throughdispersion fans, rotating platens, etc. Those known techniques can beapplied in the systems disclosed herein.

One solution to the later challenge described above is to use areceptacle constructed of a non-conductive material, e.g., a polymer.Such a receptacle would be received in an enclosure that locates the topand bottom outer walls of the receptacle approximately a quarter of awavelength of the propagated microwave frequency away from thecorresponding top and bottom walls of the enclosure. For example, if a2.45 GHz frequency microwave heating system is used, the wavelength isabout 12.2 cm. One quarter of the wavelength is a distance of 3.05 cm or1.2 inches. Thus, a metal enclosure that holds a plastic receptacle inthe enclosure to maintain a gap between the top and bottom enclosurewalls and corresponding receptacle walls of 1.2 inches would create aheated region roughly aligned with the center of the receptacle asmeasured between the top and bottom walls of the receptacle. The use ofthe top and bottom walls of the enclosure and the receptacle areillustrative only, other orientations of the receptacle relative to theenclosure are within the scope of the invention.

Meanwhile, another solution to the later problem when still using analuminum receptacle or other conductive materials uses a relativelyhigher frequency microwave signal. Advantageously, the dielectric losscoefficient for water and ice increases with increasing frequency up toabout 18 GHz. The dielectric heating effect is also proportional to thefrequency as the energy converted to heat is the same for every cycle ofvibration a molecule goes through. This combination suggests a frequencyof 18-24 GHz would work well in this embodiment because the null zonebetween receptacle wall and the heated region would be in the range ofabout 0.12-0.16 inches. Optionally, a waveguide is used to deliver themicrowave energy (instead of a coaxial cable). For example, for afrequency of 24.125 GHz (the highest allowable microwave frequencywithin the industrial-scientific-medical bands set aside for open use bythe FCC and similar agencies worldwide), the optimum waveguidedimensions are 0.34×0.17 inches (WR34).

FIGS. 46-48 illustrate a microwave heating system 4300 that uses amagnetron 4302 supplying a 24.125 GHZ signal through waveguide 4303 to atransmitting horn 4304, through a partially microwave transparent cavityend plate 4301 into the open space 4318 defined by the chamber body 4314(when the chamber is closed). A metallic receptacle and the frozenliquid contents therein receive the microwave energy. Modifications andadditions to the basic illustrated design to insure optimum signalimpedance matching, protecting the magnetron from back scatter, etc.,are within the knowledge of one skilled in the art. Moreover, for any ofthe embodiments described herein employing electromagnetic radiation asthe secondary heating source, portions of the chamber that hold thereceptacle are opaque to the wavelengths the secondary heat source usesto heat the receptacle and/or the frozen contents. In someimplementations, only a “window” into the chamber permits theelectromagnetic radiation to enter, while the rest of the chamber doesnot permit the energy to pass through the remaining walls. The chamberwalls are optionally insulated to reduce heat loss from the chamber.

FIG. 50 is an isometric view of an infrared heating system 4400. Heatingsystem 4400 is yet another example of a secondary heat source. Thefrozen contents contained within receptacle 4410 can also be melted andheated using an infrared (IR) heater. In some embodiments, the heatsource 4403 is a combined IR heater and reflector powered by an on-boardpower supply (not shown). In some embodiments, this IR heater emits anIR spectrum centered on about 2-2.5 microns, corresponding with a blackbody emitter of approximately 1200° K, to match an optimum absorptionband for water and ice. In some embodiments, a band pass filter 4402allowing radiation in the range of about 2.0-3.3 microns to reach thereceptacle 4410 is disposed between the heat source 4403 and thereceptacle 4410. Such a filter reduces high absorption peaks typical ofpolypropylene or polyethylene materials used for covering and sealingreceptacle 4410. Reducing the energy at these absorption peaks reducesthe likelihood of melting the lid material while heating the frozencontents. In some embodiments, the IR heater is an incoherent lightsource. In some embodiments, the heater is an infrared laser system. Insome embodiments, the laser system includes beam expander optics toenlarge the coherent beam to match the full diameter of the receptacleor some smaller diameter inside of the perforation needles.

In some embodiments, the dispenser may have predetermined heating andagitation functions for each receptacle that do not change regardless oftemperature and content of the receptacle. The settings may beestablished to provide beverages at an acceptable temperature fromfrozen receptacles of varying temperatures. However, in certainimplementations, the inclusion of thermal sensing equipment and systemsfor and techniques of receiving information about the frozen content orthe receptacle give the dispenser the capability to process andformulate, via certain equations of state and/or a table of inputs andoutputs, the variables of the beverage making process to achieve abeverage of a desired flavor, potency, volume, temperature, and texturein a timely manner.

The thermal sensing equipment incorporated within the dispensingapparatus may include any type of sensor including but not limited toRTDs, thermistors, thermocouples, other heat sensors and infrared energysensors. Alternatively, a temperature indicating strip created, forexample, using a variety of different thermochromic inks may be includedon the receptacle to visually signal the temperature within thereceptacle via a change in the appearance or properties of thetemperature strip. This temperature strip could be both a signal to aconsumer as to whether the pod is properly frozen before loading intothe dispensing apparatus and used by the dispenser via some type ofcamera/monitor to translate the visual signal into an electronicreading. Some embodiments of the thermochromic inks are based on leucodyes which are sensitive to heat and transition from transparent toopaque/colored as the temperature is reduced to their activation point.In some embodiments, these leuco dyes are configured in a strip of smallprinted squares on the outside of the receptacle, each square of adifferent leuco dye formulation, and ordered such that as thetemperature of the cup falls, the length of the strip that isopaque/colored steadily grows in length or changes in shape.

Similarly, as a means to alert the consumer that the receptacle may havebeen exposed to an unacceptably high temperature prior to use, in someembodiments the outside of the receptacle may include an area coveredwith a material which irreversibly changes color if some activationtemperature is reached or exceeded. Systems of this type, based forexample on colored paper and a special wax formulated to melt at thedesired temperature, are well known in the art.

As mentioned elsewhere herein, the receptacle may include a barcode, QRcode, marking, image, number or other type of glyph to conveyinformation about the frozen content or receptacle to the dispenser viaan optical sensor. In some embodiments this information is encrypted tocreate a barrier to imitation by other producers. Without the code, thedevice stays inactive and/or will refuse to accept the receptacle.Alternatively, without the code the dispenser operates to deliver abeverage, but only with a reduced set of functions that may not yield anoptimum user experience. The optical sensor may be an optical switch,camera or laser configuration and use any type of photoconductive,photovoltaic, photodiode, or phototransistor device. The receptacle mayalternatively include electrically resistive printing that defines whatbeverage it contains. Simple probes mounted in the dispenser contact thepaint to read the resistance.

The receptacle may alternatively include a physical structure acting asa key to define a property of the frozen contents within. In someembodiments, this geometry of the receptacle is detected by thedispenser and, based on this special geometry, various settings forbeverage creation are adjusted to correspond with factory oruser-generated parameters for that beverage.

In some embodiments, a probe could be used to pierce the receptacle andidentify the contents based on spectrometry, chromatography, or otherknown techniques to identify compositional features. In otherembodiments, a communication system utilizing electromagnetic sensors inthe dispenser and compatible electromagnetic labels embedded in thereceptacles (e.g., using RFID, NFC, Blue Tooth™ or the like) passinformation about the frozen contents to the dispenser. In anotherembodiment, the receptacle could be weighed using a scale/weight sensorand a mass could be assigned to different products as a method ofdifferentiation. Similarly, a mass sensor could be used to directlydetermine the mass of the filled receptacle.

The information detected by the dispenser may include the composition ofthe frozen contents or be a derivative thereof that may indicate themass and/or certain thermodynamic properties of the content. In someexamples, the contents could be classified by its amount of protein,fat, carbohydrates, fiber, ash or other food components. In otherembodiments, it could be identified by a category, like juice, or asub-category, like orange juice, that group receptacles with similarthermodynamic properties and desired drinking temperatures. With themass, temperature, and a thermodynamic understanding of the frozencontent the dispenser may use a microprocessor to adjust its beveragecreation settings to carefully melt, dilute, and heat the frozencontents to a desired volume, potency, temperature, texture, etc.

Alternatively, the receptacle may include a representation of thethermodynamic properties derived from the frozen content's compositionin the form of certain key variables. These thermodynamic properties andother properties acting as inputs may include, but are not limited to,mass, shape, density, specific heat, enthalpy, enthalpy of fusion,enthalpy of vaporization, thermal conductivity, thermal capacity,initial freezing point, freezing point depression, thermal diffusivityor any combination or derivation of the sort that is descriptive ofmelting and reheating properties. Other information about the frozencontent and/or the receptacle includes volume of fill and/or headspacepresent in the receptacle.

In some embodiments, the information conveyed to the dispenser fordetermining certain process variables may include the date ofmanufacture. For example, in some embodiments the food components withinthe receptacle may include fresh fruit or vegetables which generate heatthrough respiration and lose moisture through transpiration. All ofthese processes should be included for accurate heat transfercalculations. In rare occasions, changes in thermodynamic propertiesbased on a time variable should be accounted for. In other embodiments,the date of manufacture could be of importance in determining whethercertain age sensitive components in the frozen contents have exceeded anallowable shelf life, which is optionally included in the informationconveyed to the dispenser. In such embodiments the dispenser could beprogrammed to reject the receptacle and prevent its processing for thesafety of the user.

The determination of beverage creation functions and settings mayinclude an equation with one or more variables. For example, thedispenser could use temperature, mass, specific heats, and enthalpy offusion in a multi-variable equation to determine the most efficient wayto prepare a beverage or liquid food product to deliver it to theconsumer's cup at a specific temperature, consistency, and volume.Alternatively, the determination of settings and functions may be basedon a processor using a table of inputs and outputs in a database. Forexample, a receptacle with a detected category and temperature may beincluded in a database and thereby associated with variable functions tomelt, dilute, and reheat. The database may be stored within thedispenser or at a remote location and accessed via a communicationsnetwork. In some embodiments, a combination of equations and tables ofinputs and outputs may be used to determine the proper beverage creationsettings, including adjustments for dispenser altitude, voltage and inuse voltage drop.

Every combination of mass and temperature of a frozen compositionrequires a certain amount of energy be added to enable it to be meltedand heated to the desired temperature with a diluting liquid and othermeans of melting and reheating. In a thermodynamic modeling equation forcreating a liquid food product at a desired temperature it is importantto account for heat energy lost to atmosphere, receptacle walls, andother similar effects. In addition, ambient conditions in theenvironment where the product is being created may also play a factor inachieving a desired final temperature of a dispensed product.Embodiments of the dispensers described herein take into account suchvariables when determining the process and setting for productpreparation.

The adjustable settings may include, but are not limited to, theduration, sequence, timing, amount, pulsing of the incoming dilutionliquid, high pressure air during dispense or frequency of supplyingheat, agitation, or other form of energy to a frozen contents, a periodof rest between periods of agitation at specific points in thedispensing, the total diluting liquid volume, the diluting liquidtemperature, a change in diluting liquid temperature, the rate of liquidinjection (including pauses in the injection), the pressure of liquidinjection, the positioning of the receptacle, the perforation locationon the receptacle, the size of the perforation, the shape of theperforation, when a perforation is made, the number of perforations andany follow-up cleaning function such as a rinse of the injection cavityor maintenance notification. The variability, sequence, timing,reoccurrence, duration and combination of these functions may beimplemented in many different ways to create a liquid product withdesired characteristics. In further embodiments, the dispenserincorporates and adjusts the use of air to be co-injected with thediluting liquid as a supplement to the diluting and/or melting liquidadded to the receptacle as a means to improve mixing of the contents andthe efficiency of liquifaction.

In some embodiments, these functions may be combined to create abeverage in the least amount of time or using a minimum amount ofenergy. In some embodiments, the amount of time for a source of heat toachieve a certain temperature may be included in determining thebeverage creation settings. For example, a heated diluting agent may bea faster source to melt the frozen content, but takes far longer toreach a certain required temperature of the frozen contents than wouldotherwise be required if that energy were added using electromagneticradiation. As an example, a machine may be programmed to use moreelectromagnetic radiation to heat the frozen contents if the dispenserwas only recently powered on and the temperature of the cavity or waterin the heater tank is low. Conversely, if the water tank with thediluting agent is already hot, then the dispenser may revert to lesselectromagnetic radiation to create a desired product faster.

Alternatively, the combinations of these functions may be used to createa more uniform consistency when dispensing. For example, the settings ofthe dispenser may be adjusted to create a steady melting rate of thefrozen contents or just the external portion of the frozen content so asto initiate flow so that potency of the liquid product is consistent fora longer duration of the dispense.

In some embodiments, the dispenser reads the temperature of a dispensedliquid and continually adjusts the beverage creation settings throughoutthe dispensing process. In some embodiments, a non-diluting heat sourceand a diluting agent may work harmoniously in the beverage creationcavity to heat, melt and/or dilute the frozen content.

In some embodiments, the dispenser has refrigeration components thatchill a diluting agent for melting and diluting the frozen contents tocreate colder beverages. So long as the injected chilled diluting agentis warmer than the frozen contents, it will still act as a thermalresource for thawing the frozen contents.

In some embodiments the backpressure of the incoming liquid is measuredwith a pressure sensor to allow changes to the dispensing process forthe diluting/melting liquid. For example, if a pressure higher than athreshold is detected, it may be the result of an insufficient flow pathfrom the inlet, past the frozen contents, to the outlet. In such a case,the dispensing pump injecting liquid into the receptacle can be stoppedtemporarily to allow for some melting of the frozen contents to occurand, thereby create a larger/better flow path to the outlet before moreliquid is added. This feature may prevent loss of liquid outside thereceptacle or dispenser and lead to greater accuracy in the overallvolume of the dispensed product.

In some embodiments, the desired potency, volume, texture, temperature,or other beverage characteristic is programmed or selected from a rangeof options by the consumer. The dispenser may take this desired outputin combination with temperature and compositional information about thefrozen contents to carefully adjust settings to create the desiredfinished product.

Although there are many possible embodiments for taking temperature andcompositional information from a frozen liquid pod to adjust settings tocreate a desired beverage, there should be consistent changes in theoutput of dispenser functions based on certain increases and decreasesin temperature, mass, and presence of certain compounds. In someembodiments, the dispenser will recognize and alert the user followingthe insertion of an empty/used receptacle.

In one example, a dispenser adjusts the settings for the creation of abeverage of the same volume, potency, and temperature from receptacleswith identical frozen contents, but with different initial temperatures.The receptacle that is colder will require more transferred energy tomelt and reheat the contents to a desired temperature. For the colderreceptacle, the dispenser may adjust and implement a longer pre-heat, ahotter pre-heat, a hotter diluting agent, or more agitation to add theenergy necessary to increase the temperature of the finished beverage toyield a final beverage that is nominally the same as one created fromthe initially warmer pod, ceteris paribus. Any described beveragecreation settings above may be combined strategically to transferadditional energy to the colder receptacle.

It is understood that the mass and BRIX of a frozen content within areceptacle impacts the energy needed to melt and reheat the content to acertain temperature. In another embodiment, a user may choose fromdifferent size and potencies of a finished product at a standardtemperature. This would require less or more of a diluting liquid, heat,and agitation supplied to the frozen content depending on thevolume/potency selection.

The composition of the frozen contents dramatically impacts thetemperature of a finished beverage with uniform liquid product creationsettings. Each makeup of frozen contents at a given mass and temperaturerequires a certain amount of energy transferred to melt and reheat thecontents. It should be understood that many additives impact thethermodynamic metrics of a composition. Detecting these differences inthe frozen content receptacles allows the dispenser to adjust itssettings to provide for a desired finished liquid product from thefrozen contents. For example, a dispenser may adjust its settings tocreate a beverage of the same volume and temperature from receptacleshaving the same mass, but with one pod having a higher sugar contentthan the other. The additional sugar in one receptacle depresses thefreezing point of the content and it impacts the specific heat, enthalpyof fusion, thermal conductivity, and more such that it requires adifferent amount of energy and/or melting environment to create abeverage of the same volume and temperature as the receptacle with lesssugar content. Techniques are known for estimating the heatcharacteristics of foods and beverages and can be used with embodimentsof the inventions herein.

As described, the dispenser can derive some thermal propertyrepresentation of the frozen content in a variety of ways. Thisinformation can include multiple variables for increased precision of afinal beverage. Alternatively, the information can be a single variablethat represents a baseline of the ease of melting and reheating. Someexamples of thermodynamic properties and how they may impact thebeverage creation settings are described below.

Thermal conductivity is the property of a material to conduct heat.Increased thermal conductivity will facilitate the heat being uniformlydistributed throughout the frozen contents. Thermal conductivity is alsovery important at the interface between the frozen contents and anydiluting liquid and may be increased by agitation applied to the frozencontent or other efforts to disrupt the thin surface layer of otherwisestagnant fluid at the interface. In general, increases in the amount offood components including, protein, fat, carbohydrates, fiber, and/orash comprised in the frozen content will increase the thermalconductivity of the content.

Enthalpy of fusion, also known as the latent heat of fusion, is thechange in system enthalpy required for the state to change from a solidto a liquid at the same temperature. In the case of this dispensingsystem, the enthalpy of fusion is the amount of energy required to melta quantity of the frozen contents once it has already been warmed to itsmelting temperature. Enthalpy of fusion plays an important role in theability of this dispenser system to create chilled beverages from frozencontent without the use of a secondary mechanical cooling system becausea significant amount of heat can be removed from the diluting liquid.The greater the enthalpy of fusion of the frozen content, the moreenergy it will take to melt the contents. Therefore more energy will berequired to melt and reheat the frozen contents to a certain temperaturefor products with a higher enthalpy of fusion.

Thermal capacity or heat capacity is a measurable physical quantitydetermined as a ratio of heat given or taken from an object to theresulting temperature change of the object. Specific heat, a measurewhich is independent of the mass of an object, is described in metricunits as the heat required to raise the temperature of one gram ofmaterial by one degree Kelvin. similar to enthalpy of fusion, thespecific heat of a given composition plays an important role in theamount of heat necessary to first increase the temperature of the solidfrozen composition to its point of fusion, and then to further heat thecontents once it is a liquid. It is important to note that the specificheat may differ when a composition is in liquid versus solid form. Forexample, the specific heat of water in its solid form is about half ofits value for its liquid form. This means it requires about half theenergy to increase frozen water one degree Celsius as compared to asimilar mass of liquid water.

It is important when calculating the beverage creation settings for thedispenser that these variables are highly inter-related. The entirereaction environment must be considered in making any adjustment for newconditions. For example, merely accounting for the amount of heat energyfrom the diluting liquid and/or an alternative heat source will notyield the desired final product equilibrium temperature if variablessuch as agitation and dilution liquid flow rate are not considered. Forexample, the flow rate, pressure, and agitation supplied to receptaclemay be used to increase the thermal transfer between the supplied heatand the frozen content.

One embodiment of an algorithm for preparing a completely liquidfood/beverage from a frozen content:

-   -   input: scan pod bar code or QR code to gather:        -   content mass (M_(fc))        -   content volume when liquid (V_(fc))        -   melting point of content (T_(mp))        -   latent heat of fusion of content (H_(fc))        -   specific heat capacity of solid content (c_(s)—use average)        -   specific heat capacity of content when liquid (c_(l)—use            average)        -   final product acceptable temperature range        -   final product acceptable volume range    -   input: dispenser thermal sensor determines frozen content        temperature (T_(fc))    -   input: user provided desired volume (V_(d)) and temperature of        final product (T_(d)), limited by scanned ranges (or these        values are set by coded information)    -   input: dispenser thermal sensors determines ambient water        temperature (T_(a)) and hot water temperature (T_(h))    -   determine: amount of heat needed to bring entire frozen content        to melting point and then to liquefy the entire content (Q_(l)):        Q _(l)=[M _(fc) ×c _(s)×(T _(mp) −T _(fc))]+H _(fc)    -   T_(mp) will likely be an empirically determined temperature        rather than a sharp melting point for “mixed” foods/beverages    -   determine: amount of heat needed to bring liquid content at        melting point to desired product temperature, accounting for        heat loss during the beverage creation process (Q_(d)):        Q _(d) =M _(fc) ×c _(l)×(T _(d) −T _(mp))    -   determine: amount of excess heat available from hot dilution        water (Q_(ex)):        Q _(ex)=(V _(d) −V _(fc))×(volumetric heat capacity)×(T _(h) −T        _(d))    -   determine: amount of additional heat needed, if excess from        dilution is not enough (Q_(add)):        if Q _(ex) <Q _(l) +Q _(d) : Q _(add) =Q _(l) +Q _(d) −Q _(ex)    -   for the supply of this additional heat, we will need to apply a        loss factor        -   for a microwave heat source, we will need to apply an            “absorption” factor based on food/beverage content    -   Determine: mix of hot water and ambient water, if excess from        dilution is too much:        if Q _(ex) >=Q _(l) +Q _(d):        V _(h) =V _(dil)/((T _(d) −T _(h))/(T _(a) −T _(d))+1)        V _(a) =V _(dil) −V _(h)    -   where:        -   V_(h) is volume of hot water            -   V_(dil) is volume of total dilution (V_(d)−V_(fc))            -   V_(a) is volume of ambient water or chilled water.

The duration and timing for the application of secondary (non-diluting)heat are two of many parameters that will affect the overall timing,efficiency and success (achieving a positive experience for the consumeras measured by beverage/food taste, temperature, potency, volume andrequired time/convenience) of the dispensing operation. In someembodiments all of these parameters are determined by a controlalgorithm built into the firmware or software of the system controller.Inputs to this algorithm may include user preferences for dispensedproduct temperature, volume, and strength or potency of the consumableas input by the user to an human machine interface at the start of thedispense cycle. Also included as inputs may be data gathered during ascan of the product bar code, QR code, RFID or other data transmissionmechanism that are attached to the specific product chosen by the userfor dispensing. This data may include information about thethermodynamic properties of the frozen contents; a range of dispensedvolumes the contents can supply within preferred potency limits; andwhether the contents have exceeded a recommended shelf life or whetherthey have been exposed to temperatures considered unsafe from abacterial growth perspective. And finally, data gathered may includephysical property and location information gathered from sensorsembedded in the dispenser. In some embodiments this data will includetemperature and volume of the reservoir fluid; temperature, mass andvolume characteristics of the dispenseware; temperature of thereceptacle and/or the frozen contents; knowledge about what wasdispensed during the previous cycle and when that occurred; and thealtitude where the dispenser is located since barometric pressureaffects boiling temperature and in most instances it is not desirable tocreate steam within the system or the receptacle.

With all of this information available to the system controller'salgorithm, the controller will, in some embodiments, use this algorithmto calculate/select various control values for cycle timing,temperatures, durations, liquid volumes, liquid flow rates, a decisionabout when to puncture or vent the receptacle, etc. to arrive at thedesired end point of beverage quality given all the known startingconditions. In some embodiments the system controller also makes use ofongoing data input from sensors to “learn” during the cycle and adjustongoing temperatures or durations or volumes to correct small observedout-of-spec or adverse-trending conditions. Thus the timing for lidventing or puncture, addition of secondary heating, addition of fluids,agitation timing and duration, and final dispense will all be set andadjusted in accordance with an algorithm. Over time (months or years)this algorithm can be updated via WiFi or other digital means asimprovements are developed, new products are introduced, dangerous orcounterfeit products are discovered, or unanticipated safety concernsbecome known. In some embodiments the algorithm adjusts the heating rateand maximum temperature of the frozen contents so as not to overheatcertain thermally sensitive ingredients such as orange juice and therebypreserve the freshest taste possible.

Diluting fluid injection rates can vary widely depending on the type andsize of the beverage/food product being dispensed. As discussedpreviously, these values will for some embodiments be calculated and setby the system controller. As a rough guide, however, a range of probableflow rates can be estimated, considering the creation of a 2-ounceespresso dispensed over 30 seconds on the low side and considering a 32ounce carafe dispensed over 90 seconds on the high side. These flowrates suggest a range of flows of 0.02-0.25 gallons per minute as aspecification for the fluid flow pumps. It is understood that faster andslower flow rates are within the scope of the invention, as is largerand smaller serving sizes.

In some embodiments the rate and timing of fluid flows are adjustedbased on whether the water is sourced directly from the reservoir ormust first pass through the heating chamber and whether some means isemployed to take maximum advantage of the cooling effects possible fromthe frozen contents when making a cold beverage. For example, in someembodiments ambient temperature or tempered (mixed hot and ambient)water is first used to apply some heat to the exterior of a receptacleby passing it through a water jacket in close contact with thereceptacle. As heat is passes to the receptacle, the temperature of thefluid passing through the water jacket is reduced. If this cooled watercan be captured and stored in secondary container, e.g., a pressurizeddevice (similar in function to a commercial product such as an Extroltank), then the fluid can be subsequently flowed to the interior of thereceptacle to further melt and dilute the frozen contents without use ofadditional pumps or motors. If the intermediate storage tank is largeenough, it is not necessary to worry about balancing the volumes of heattransfer fluid and what is later to be injected into the receptacle.(Excess fluid in the storage tank can be returned to the reservoir atthe end of a dispense cycle.) In this way it is possible to capture muchof the “coldness” or “negative thermal energy” of the frozen contents topermit the dispensing of cold beverages without onboard mechanicalrefrigeration inside the dispenser.

The temperature of the water added to the receptacle is an importantparameter in the dispense cycle as it greatly affects the finishedproduct temperature and weighs heavily in the consumers judgment aboutwhether the dispensed product has met their expectations. The watertemperature is controlled by the system controller via mechanisms andsensors built into the dispenser. First, ambient temperature watersupplied by the dispenser to the receptacle can be sourced directly fromthe dispenser's reservoir or be routed through a heater tank. Thereservoir water itself can also range in temperature based on the seasonof the year if it comes from the user's tap, how long it has been givento equilibrate to room temperature, and whether the user has chosen toadd ice when, for example, a cold beverage is planned. Water routedthrough the heater tank can be heated to a fixed temperature for alloperations as is common in most coffee brewers today or it can becontrolled to some other variable temperature based on output signalsfrom the system controller. Delivered water can be tempered, that is, acombination of waters sourced from a hot water tank and the cooler waterreservoir can be mixed together, with the final temperature determinedby a set of proportional flow valves and a downstream thermal sensor.Some final “fine tuning” of the temperature of the water delivered tothe receptacle can be made as it passes through a needle or tubing withsecondary heater around it. And finally, the water exiting thereceptacle can be further heated as it leaves the receptacle and flowsthrough some dispensing channel to the user's coffee cup or otherdispenseware.

It should be noted that since the device is a dispenser and not abrewer, the maximum water temperature required for proper functioningmay be considerable lower than that found in most well-known coffeebrewers today. (The water for brewers is typically supplied at atemperature between 190° and 205° F. to achieve the optimum level ofsolute extraction from, for example, coffee grounds.) Accordingly,concerns about high temperature settings that may actually exceed thelocal boiling point in some high-altitude locations can be easilyaddressed. It is possible, for example, to use a maximum temperaturesetting for the water of 180-185° F. and thereby insure the boilingpoint will not be exceeded for any location below approximately 12,000feet mean sea level. Thus, while the system controller could beprogrammed to use input from a barometric sensor or estimate altitudebased on a GPS or WiFi derived location, this complexity is not requiredto achieve excellent performance as well as operational safety relatedto boiling water concerns. In some embodiments the temperature of thewater produced by the hot water tank is kept at the hottest temperaturepossible for local conditions based on location inputs and then thatwater is tempered as needed for optimizing the thermodynamics requiredto dispense a beverage at the temperature desired by the user.

In another embodiment, the principals of machine learning are applied tothe calculation of the dispenser properties. For example, the scans ofthe pod and the temperatures of various components may be taken asinitial input. Thereafter, however, the dispenser conducts a series ofshort “experiments” to validate or refine the inputted thermodynamicproperties. For example, the secondary heat source is activated for fiveseconds and the resulting impact on temperature is noted. Given thislevel of energy input and the originally inputted properties of thefrozen contents, a specific temperature rise will be expected. If themeasured temperature rise differs sufficiently, the values for specificheat, thermal conductivity, etc. may be adjusted to more closely matchthe observed reality. These new parameter values can be used toimmediately recalculate the planned dispenser “recipe” to more closelyyield a beverage matching the users stated preferences.

In some embodiments the characteristics of the user's glass, coffee cup,bowl other container (hereinafter “dispenseware”) are also communicatedto the dispenser via bar code, QR code, RFID, or other means. Thisinformation is of interest to the dispenser to (1) ensure the receivingdispenseware for the melted and dispensed beverage liquid or food is ofsufficiently large volume to receive all of the dispensed materialwithout overflowing and (2) to better understand the cooling effect thedispenseware will have on the dispensed food or beverage so that thedispensed temperature setting for the control system can be adjusted. Insome embodiments, the temperature of the dispensed beverage, as measuredin the dispenserware after the dispensed fluid and the dispenserwarehave come to thermal equilibrium, is the temperature specified by theuser as his/her preferred beverage/food temperature.

In some embodiments the dispenser includes an active device to heat orcool the user's dispenserware before or during the time the dispenser ismelting/dispensing the frozen contents. In some embodiments this deviceis a surface plate that is heated or cooled by a thermoelectric device.In some embodiments the dispenserware communicates its actualtemperature to the dispenser for more accurate adjustment of thedispensed fluid temperature.

In some embodiments, the addition of supplemental heat is controlled tolimit the speed or localization of the liquefaction and vaporization ofthe frozen contents. In some embodiments, a non-diluting heat source mayheat the receptacle in order to melt the frozen contents therein, or thedispenser may heat an ambient temperature liquid as a diluting liquid asit travels through the receptacle and beverage creation cavity.

In some embodiments, a secondary, non-diluting heat source may beapplied to the receptacle while the receptacle is being agitated. Infurther embodiments, a diluting liquid may be dispensed through thereceptacle while it is being agitation and heated by a non-diluting heatsource. The combination of agitating while melting provides a means fora more even distribution of heat. Agitating the receptacle will allowheat to disperse throughout the receptacle instead of certain areasoverheating.

In some embodiments, the diluting liquid does not travel through thereceptacle, but rather bypasses an injection through the receptacle andis dispensed in a location proximate to the dispense location of themelted frozen content. Optionally, the cavity in which the receptacle isheld has a mixing area that receives the melted liquid product from thereceptacle and combines it with dilution liquid. In some embodiments, aperforator injected a pressurized air to rinse the receptacle clean andincrease the pressure at which the melted frozen content mixes in abeverage container with the diluting agent. This may include an aircompression system within the dispenser. The dispense of the dilutingliquid and melted frozen content may happen in unison, or one dispensemay happen before the other. In another embodiment, the dispense of theliquids could alternate multiple times. In some embodiments, an amountof the diluting liquid is dispensed through the receptacle and an amountis dispensed directly into a beverage container.

In some embodiments, water is only heated to one temperature in thedispenser, but the dispenser includes fluid paths that bypass theheating before being injected into a receptacle such that the wateradded to the receptacle is at ambient temperature. Bypassing the waterheater could be done in at least two ways: (a) a 3 way valve after thepiston pump could divert ambient water from a reservoir either through ahot water heating tank en route to the dispense head or directly intothe dispense head. See L-type Valve in FIGS. 36A and 36B, or (b) asimple tee at the base of the water reservoir may feed two separatepiston pumps in which one piston pump feeds water through the waterheater en route to the dispense head and the other piston pump feedswater directly to the dispense head as shown in FIGS. 35A and 35B. Insome embodiments, the plumbing system may include a dispense channel orbypass system to refrigerate diluting agents. Any of the describedtechniques enables the dispenser to control the temperature of thedilution liquid supplied to the receptacle.

In some embodiments, the dispenser has at least two reservoirs: one forambient water and one for water that has been heated. The dispenser alsohas fluid paths to supply hot water separately from ambient water to thereceptacle and/or final food or beverage container. In someimplementations, the dispenser includes a source of carbon dioxide andan injection path to supply the carbon dioxide to the ambient waterreservoir to carbonate the water. In other implementations, thedispenser has a separate vessel that receives water from the ambientwater reservoir or another water supply, and the carbonation systemcarbonates the water in the separate vessel. In some embodiments, watercan be carbonated in-line along a flow path. Thus, implementations ofthe invention include the ability to carbonate liquid that is supplieddirectly to the final food or beverage container.

The dispenser includes a supplemental (non-diluting) source of heat,which can include electromagnetic energy (e.g., microwaves), hot air, anelectrical heater, or other sources. The dispenser can also useagitation (e.g., reciprocating or circular motion or vibration) tofacilitate and control the melting, thawing and/or heating of frozencontents. The dispenser includes detection components (sensors)including, for example, temperature and pressure sensors, and an opticalreader for obtaining information about the receptacle and its contents.It is important to note the sources of heat, agitation, and detectioncomponents described herein are purely exemplary and these steps may beapplied with any means of heat, movement, or detection known within theart. In addition, the steps included in this embodiment are exemplaryand steps may be added and deleted to form a similar outcome.

In some embodiments, the dispensing system includes a network interfaceand is capable of being connected to a communication network, such as aLocal Area Network (LAN) or Wireless LAN (WLAN), so that it maycommunicate with other devices, e.g., a smart phone or a server systemthat records information about the dispenser's use. In some embodiments,the dispenser may record data about the dispenser's use, e.g., whatproducts are being made with it, and record the data locally to beupdated to a server when a network connection is re-established. In someembodiments this network connection can be used to diagnose issues andupdate software for new and future product parameters.

Illustrative examples of how embodiments of the dispensers describedherein vary their operational parameters and overall process to createdifferent types of liquid food or beverages follow below. Other food andbeverage types are within the scope of the invention as are other methodof operation to create such products.

In the first example, based on the detection of the beverage style and a2 oz. setting selected by the user, the dispenser creates a ventilationopening in the top lid of the receptacle to allow any internal pressuregenerated during the beverage making process to escape to atmosphere.Next, some amount of supplemental (i.e., secondary) heat (provided asset forth above) is added to warm or melt (partially or fully) thefrozen contents. In this instance, a hot beverage is desired and thebeverage creation recipe calls for too small a diluting volume of heatedwater to properly melt and heat the contents to a desired temperature.Accordingly, the preheat duration is calculated to melt the entirefrozen content and increase the temperature of the resulting liquid toabout 85° F. before dispensing or adding a diluting agent. This heat upof the frozen/melted contents to 85° F. can be accomplished either in anopen-loop manner based on knowledge of the thermal properties of thecontents or in a closed-loop, feedback driven system wherein one or morethermal sensors track the heat-up of the contents and cut power to thesecondary heater at the appropriate time. The reciprocating motion maybe applied thereafter or in unison with the supplemental heat tohomogenize the content. The intensity of the supplemental heat and itsoverall duration is also controlled to minimize the local vaporizationof any of the frozen contents to steam.

Once the approximate 85° F. temperature is reached, the perforatorlocated beneath the cavity in which the receptacle is disposed is thrustupwards through the bottom of the receptacle, perforating it andallowing the liquid content to flow out a channel of the perforator andthrough a nozzle of the dispenser into a beverage container. Aperforator with a larger diameter than the vent hole made earlier (toensure a tight fit around the periphery of the perforator) is insertedat the same location as the vent hole in the lid of the receptacle,creating a substantially leak-free fitting between the perforator andthe receptacle lid so 1.25 oz. of water heated to 190° F. can bedispensed into the receptacle to mix, dilute and dispense the meltedfrozen content to create an espresso beverage with a TDS of 7.5, volumeof 2 oz., and temperature of approximately 150° F. The hot waterinjection occurring at the end of the dispense cycle rinses thereceptacle clean of all extract to optimize the suitability of thereceptacle for recycling. Agitation may be added in sync with thedispensing of the hot diluting agent to better flush the receptacle anddispensing channels of any residue. The empty receptacle may then beremoved and recycled.

In a second example, a 1 oz. receptacle contains 0.5 oz. of a frozenconcentrated tea extract with a TDS of 40 and 0.25 oz. of a frozen peachconcentrate with a Brix of 50, intended to create a hot peach green teabeverage. The dispenser gathers information from marks or otherindicators on the receptacle, and for this beverage, does not provide anoption to select a volume (the options being controlled by theinformation associated with the receptacle). Following receptacledetection, a button blinking red on the dispenser may communicate thebeverage will be dispensed hot. The dispenser establishes a recipe basedon the information associated with the receptacle detected by thedispenser. In this example, the dispenser establishes a pre-heatduration, time of puncture, time of injection, temperature of dilutingliquid, and volume of diluting liquid based on information acquired. Asin the example above, the receptacle is next loaded into the beveragecreation cavity of the dispenser and secured in place, resting on anintermediate step in the cavity that accommodates more than onereceptacle size.

Once the receptacle is secured, the user may initiate one final action,e.g., the press of a button on the dispenser or a connected device, tocommence automated functions for product creation. Based on thedetection of the beverage style settings, the dispenser creates a ventopening in the top lid of the receptacle and a supplemental preheatduration is initiated to only soften and liquefy an outside portion ofthe frozen content so the perforator beneath the step can penetrate thereceptacle without great force, displacing the frozen content away fromthe entry point, if needed. After the outlet perforator has perforatedthe receptacle, a perforator with a larger diameter than the vent holein the lid is inserted at the same location as the vent hole in the lidof the receptacle. This creates a tight fitting for the addition of 7.25oz. of water heated to approximately 190° F. (as calculated by theprocessor based on the original recipe and subsequently modified basedon an actual temperature measurement made of the receptacle at theconclusion of the preheat), which will be dispensed into the receptacleto mix, melt, dilute and dispense with the receptacles content to createan 8 oz. beverage with a desired concentration of green tea and peachflavoring.

The pre-heat function and 7.25 oz. of approximately 190° F. dilutingagent bring the final dispensed product to a temperature ofapproximately 150° F. The hot water injection rinses the receptacleclean of substantially all contents, and again, agitation may be addedin sync with the dispensing of hot diluting agent to better flush thereceptacle and dispensing channels of any residue. The agitation mayalso increase the melting rate of the frozen content and provide for alonger rinse of pure water for sanitation. The empty receptacle may thenbe removed and recycled.

A second, higher capacity receptacle is designed to provide for, e.g., acold single-serve beverage, a single-serve relatively larger hotbeverage that includes components that are more difficult toconcentrate, e.g., dairy, and large batch servings of hot beverages. Inone example, a 2.25 oz. receptacle contains 2 ounces of a frozenconcentrated orange juice with a BRIX of 47.2 intended to create an 8oz. cold serving of juice. The dispenser gathers information about thefrozen contents in the receptacle (by, e.g., reading an optical mark onthe receptacle with an optical sensor) and establishes the necessaryprocess settings to create an 8 oz. cold orange juice qualifying by FDAstandards as 100% juice (BRIX of 11.8) from the receptacle contents. Inaddition, following receptacle detection, a button on the front of thedispenser blinks blue to communicate the beverage is a cold one, andperhaps remind the user to use the appropriate cup to receive the finaldispensed product. (Optionally, the dispenser may have a sensor whichchecks for the presence of a glass or cup of the minimum size needed toreceive the full 8 ounce serving.)

In this example, the dispenser establishes a pre-heat duration, time ofpuncture, time of injection, temperature of diluting liquid, volume ofdiluting liquid, and a flow rate of the injected diluting liquid basedon information acquired by the dispenser. The receptacle is next loadedinto the beverage creation cavity of the dispenser and is secured inplace. The bottom depth of the cavity also has a perforator, and in thisembodiment, can puncture inwards of the receptacle, retract, and alsomove side to side with its connected tubing to create a dispense channelcapable of moving with agitation used to enhance liquefaction of thefrozen contents. The perforator is initially positioned beneath thebottom depth of the cavity and does not enter the receptacle. Once thereceptacle is secured the user may initiate one final action, e.g., thepress of a button on the dispenser or a connected device, to commenceautomated functions for product creation.

Based on the detection of the beverage style, the dispenser creates avent opening in the lid of the receptacle and initiates a period ofsupplemental preheat to only melt the outer-most portions of the frozencontent inside the receptacle while keeping the majority of the contentfrozen. In this instance, because the desired beverage is to be cold,the enthalpy of fusion of the frozen content is to be used to lower thetemperature of a diluting liquid to chilled temperatures. After theouter portion of the frozen orange juice content is melted, asdetermined open-loop by knowledge of the frozen contents and the amountof energy added or as determined closed-loop via information gathered byone or more thermal sensors, the perforator located beneath the bottomdepth of the cavity is thrust upwards into the receptacle, perforatingit and allowing the liquid content to flow out a channel of theperforator, through a nozzle in the dispenser, and into a beveragecontainer. In addition, another perforator, this one with a largerdiameter than the vent hole in the lid, is inserted at the same locationas the vent hole in the lid of the receptacle, creating a tight fittingseal and allowing for delivery of about 6 oz. of ambient water into thereceptacle at a slower rate than typically used for hot beverages togive the cooler injected liquid more time to interact with the frozencontents and promote fully melting the contents. Agitation is added toexpedite the mixing of the frozen content and the diluting liquid to thetarget potency and temperature. In this way, the dispensed productcreated may reach refrigerated temperatures when equilibrium is reachedbetween the frozen content and the ambient temperature diluting agent.The final product is a chilled glass of orange juice with a Brix of11.8, meeting the FDA standard for 100% orange juice.

In another illustrative example, a 2.25 oz. receptacle contains 1 oz. offrozen condensed milk, ½ oz. of frozen heavy cream, 10 grams of sugar,and ½ oz. of a frozen coffee extract with a BRIX of 24, collectivelyintended to create a hot serving of a café latte. The dispenser reads avisual mark on the receptacle with an optical sensor and establishes theprocess settings to create an 8 oz. hot latte with a coffeeconcentration of 1.5% TDS and target dairy and sweetness levels. Inaddition, following receptacle detection, a button blinking red on thefront of the dispenser may communicate the beverage will be dispensedhot.

In this example, the dispenser establishes a pre-heat duration, time ofpuncture, time of injection, temperature of diluting liquid, volume ofdiluting liquid, and the flow rate of the injected diluting liquid basedon information acquired by the dispenser from the receptacle markings.As in the examples above, the receptacle is next loaded into thebeverage creation cavity of the dispenser and is secured in place. Oncethe receptacle is secured the user may initiate one final action, e.g.,the press of a button on the dispenser or a connected device, tocommence functions for product creation. The dispenser creates a ventopening in the lid of the receptacle and initiates a period ofsupplemental heating to melt the majority of the frozen content. Asbefore, this period of time can be open-loop or closed-loop controlled.In this instance, since the desired beverage is to be hot and a full 2oz. of frozen content must be melted and heated, a longer preheat isrequired than a similar sized hot coffee beverage created from the firstlower capacity receptacle.

After the majority of the mass of the frozen content is melted, based onthermal sensor readings and/or total energy input, the perforatorlocated beneath the bottom depth of the cavity is thrust upwards intothe receptacle, perforating it and allowing the liquid content to flowout a channel of the perforator, through a nozzle of the dispenser, andinto a beverage container. In addition, a perforator with a largerdiameter than the vent hole in the lid is inserted at the same locationas the vent hole of the receptacle, creating a tight fitting seal aroundthe penetrator for delivery of 6 oz. of water, heated to 190° F. by thewater heater, to the receptacle. The water fully melts any remainingfrozen content, mixes with, dilutes, and heats the content of thereceptacle to allow dispensing of a beverage of the target temperatureand potency. Agitation and flowrate may be controlled to homogenize themelted contents and the dispensing liquid as much as possible within thereceptacle.

In a further illustrative example, a 2.25 oz. receptacle contains 2 oz.of a frozen coffee extract with a BRIX of 44.8 intended to create alarge batch serving of coffee. The dispenser reads a visual mark on thereceptacle with an optical sensor and establishes the process settingsto create 64 oz. of hot coffee with a TDS of 1.4. The dispenser maydetect the water level in the reservoir and instruct the user to addmore water if necessary. Following receptacle detection a buttonblinking red on the front of the dispenser may be used to communicatethe beverage is hot and a reminder may notify the user to use a largebeverage container to receive the dispensed product. Or the dispensersenses the presence of a carafe which has been designed to be easilydetected (e.g., proximity sensor, RFID chip, bar or QR code, etc.) bythe dispenser as being suitable for a 64 oz beverage serving. In thisexample, the dispenser establishes a pre-heat duration, time ofpuncture, time of injection, temperature of diluting liquid, volume ofdiluting liquid, and the flow rate of the injected diluting liquid basedon information acquired by the dispenser.

As in previous examples, the receptacle is next loaded into the beveragecreation cavity of the dispenser and is secured in place. Once thereceptacle is secured the user may initiate one final action, e.g., thepress of a button on the dispenser or a connected device, to commencefunctions for product creation. The dispenser creates a vent opening inthe lid of the receptacle and a period of supplemental heating isinitiated to melt a small outside layer of the content frozen. In thisinstance, the beverage with be diluted with a large amount of heatedliquid and requires a minimal preheat only to soften the frozen contentsfor receptacle perforation. Once the preheat has commenced, theperforator located beneath the bottom depth of the cavity is thrustupwards into the receptacle, perforating it and allowing the liquidcontent to flow out a channel of the perforator, through a nozzle of thedispenser, and into a large beverage container. In addition, aperforator with a larger diameter than the vent hole in the lid isinserted at the same location as the vent hole in the top lid of thereceptacle, creating a tight fitting seal for delivery of 62 oz. ofwater, heated to 190° F. The added water melts any remaining frozenportions of the contents, mixes with, dilutes, heats and dispenses thecontents of the receptacle to create a large batch serving of coffee.

Any of the dispenser system embodiments herein can include a drip traydisposed beneath any or all of the components of the dispenser system.For example, the drip tray can be contained within the lowest part ofthe dispenser housing such that any uncontained liquid generated by anypart of the dispenser is captured by the drip tray. Also, because thefinal product is dispensed into a container, such as a thermos, mug,cup, tumbler, bowl, and/or the like, the product container can be placedon a portion of the drip tray that has a grated opening to captureoverflow or spillage. The drip can be disposed below the product outletand/or diluting liquid outlet to capture liquid in the event that theproduct container is removed during the product making process. The driptray is removable from the dispenser system, and can be removed manuallyor be motor driven. Optionally, the dispenser has a level sensor thatdetects a liquid level in the drip tray and alerts the user to empty thedrip tray when a liquid threshold is reaches. Further, the dispenser canhalt the final product creation process if the dispenser detects a highliquid level in the drip tray.

Optionally, many of the parts of the various embodiments of thedispenser systems described herein are removable and dishwasher-safe.That is, the parts may be cleaning using a standard commercial orresidential dishwasher without suffering ill effects. For example, allor parts of the chamber, the perforator(s) used for dilution liquidsupply inlets, the perforator(s) used for product outlets, and all orparts of the drip tray assembly can be cleaned in a standard dishwater.Alternatively, or in addition, certain implementations includeself-cleaning mechanisms. For example, the dispenser may pass hot liquidor steam through the various liquid flow paths, chambers, vessels, andreservoirs to clean and sanitize those elements. Also, a UV light sourcemay be included in areas of the dispenser that are prone tocontamination to service as a way to clean those portions. For example,the chamber that holds the receptacle can contain a UV light source thatexposes the inside of the chamber and/or the dilution liquidperforator/injector and final product outlet/perforator to UV light.

In another aspect of the invention, any of the dispenser systemsdescribed herein can be implemented without a chamber to hold thereceptacle that contains frozen liquid contents. Rather, in thealternative implementations, the dispenser systems include an externalconnection that mates with a complementary connection on a frozencontents receptacle. The complementary connections enable the dispensersystem to provide dilution liquid to the inside of the receptacle whileminimizing leaks. Optionally, the receptacle inlet connection has aninlet seal that ruptures to permit dilution liquid flow into thereceptacle. In some embodiments, the receptacle is a pouch that expandswhen the diluting liquid is injected. In other embodiments, the pressureof injected diluting liquid ruptures an outlet seal to provide an exitfor a final food or beverage product. Although the receptacle isexternal to the dispenser, the various techniques for the dispenserlearning information about the receptacle and/or the frozen liquidcontents and the techniques for controlling the final productpreparation are equally applicable.

Aspects of the techniques and systems related to producing a food or abeverage at a desired temperature and a desired volume and in anautomated fashion as disclosed herein may be implemented as a computerprogram product for use with a computer system or computerizedelectronic device. Such implementations may include a series of computerinstructions, or logic, fixed either on a tangible/non-transitorymedium, such as a computer readable medium (e.g., a diskette, CD-ROM,ROM, flash memory or other memory or fixed disk) or transmittable to acomputer system or a device, via a modem or other interface device, suchas a communications adapter connected to a network over a medium.

The medium may be either a tangible medium (e.g., optical or analogcommunications lines) or a medium implemented with wireless techniques(e.g., Wi-Fi, cellular, microwave, infrared or other transmissiontechniques). The series of computer instructions embodies at least partof the functionality described herein with respect to the system. Thoseskilled in the art should appreciate that such computer instructions canbe written in a number of programming languages for use with manycomputer architectures or operating systems.

Such instructions may be stored in any tangible memory device, such assemiconductor, magnetic, optical or other memory devices, and may betransmitted using any communications technology, such as optical,infrared, microwave, or other transmission technologies.

It is expected that such a computer program product may be distributedas a removable medium with accompanying printed or electronicdocumentation (e.g., shrink wrapped software), preloaded with a computersystem (e.g., on system ROM or fixed disk), or distributed from a serveror electronic bulletin board over the network (e.g., the Internet orWorld Wide Web). Of course, some embodiments of the invention may beimplemented as a combination of both software (e.g., a computer programproduct) and hardware. Still other embodiments of the invention areimplemented as entirely hardware, or entirely software (e.g., a computerprogram product).

As will be apparent to one of ordinary skill in the art from a readingof this disclosure, the present disclosure can be embodied in formsother than those specifically disclosed above. The particularembodiments described above are, therefore, to be considered asillustrative and not restrictive. Those skilled in the art willrecognize, or be able to ascertain, using no more than routineexperimentation, numerous equivalents to the specific embodimentsdescribed herein.

What is claimed is:
 1. A method of producing a melted food or beverageliquid product from a receptacle containing frozen liquid contents,comprising: receiving a receptacle in a chamber of a dispenser, thereceptacle defining an enclosed inner volume containing a frozen liquidcontents; supplying a dilution fluid to the inner volume of thereceptacle when held in the chamber through a dilution fluid inletdisposed at a first location of the chamber; perforating the receptacleusing a perforator disposed at a second location of the chamber to forma product outlet from the receptacle for a food or beverage liquidproduct; imparting motion to the receptacle to increase a flow path fromthe dilution fluid inlet to the product outlet taken by at least aportion of dilution fluid, when supplied, relative to a flow path fromthe dilution fluid inlet to the product outlet taken by the portion ofdilution fluid without the imparted motion.
 2. The method of claim 1,wherein imparting motion to the receptacle further increases a thermaltransfer rate between the frozen contents and the supplied dilutionfluid relative to a thermal transfer rate between the frozen contentsand the supplied dilution fluid without the imparted motion.
 3. Themethod of claim 1, wherein the motion imparted comprises one or more of:a rotary motion, a reciprocating motion, a vibratory motion, a rockingmotion, or a shaking motion.
 4. The method of claim 1, wherein impartingmotion to the receptacle further increases an average duration of timethe supplied dilution fluid flows in the inner volume of the receptaclerelative to an average duration of time the supplied dilution fluidflows in the inner volume of the receptacle without the imparted motion.5. The method of claim 1, wherein the dilution fluid inlet is disposedabove the product outlet.
 6. The method of claim 1, further comprisingdispensing the melted food or beverage liquid product from thereceptacle.
 7. The method of claim 1, further comprising one or more of:heating the dilution fluid, cooling the dilution fluid, carbonating thedilution fluid, or pressurizing the dilution fluid.
 8. The method ofclaim 1, wherein the dilution fluid is selected from the groupconsisting of a liquid, a gas and combinations thereof.
 9. The method ofclaim 1, wherein the perforator comprises a heater.
 10. The method ofclaim 1, wherein dispenser further comprises a reservoir configured tohold the dilution fluid.
 11. The method of claim 10, wherein thereservoir includes one or more of a sensor configured to detect anamount of the dilution fluid within the reservoir or a flow rate sensorconfigured to measure a rate of fluid as used by the dispenser.
 12. Themethod of claim 1, wherein the dispenser further comprises anon-diluting heater configured to heat one or more of the receptaclewhen held in the chamber or the frozen contents within the receptaclewhen held in the chamber, wherein the non-diluting heater does not addliquid to an interior of the receptacle when held in the chamber. 13.The method of claim 12, wherein the non-diluting heater is one or moreof: a heater in contact with walls of the chamber, a heater incorporatedinto walls of the chamber, a heater spaced apart from walls of thechamber and configured to transmit energy to one or more of thereceptacle or the frozen liquid contents by one or more of radiation orconvection, an electric heater, a heated gas generator, a heated liquidbath, an electromagnetic radiation generator, a thermoelectric heater, aheated perforator, or a chemical heater.
 14. The method of claim 1,wherein the chamber includes at least one chamber wall, and wherein theat least a portion of the chamber wall is opaque to a selected range ofwavelengths of electromagnetic radiation, and the at least a portion ofthe chamber wall comprising insulation.
 15. The method of claim 1,wherein one or more of the chamber, the perforator, or the dilutionfluid inlet is removable from the dispenser and is dishwasher safe. 16.The method of claim 1, wherein the chamber defines a cavity having anopen end and the chamber comprises a movable cover configured to sealthe open end of the cavity.
 17. The method of claim 16, wherein thechamber includes a lock to releasably retain the cover in the sealedposition over the open end of the cavity.
 18. The method of claim 1,further comprising injecting a pressurized gas into the enclosed innervolume of the receptacle through one or more of the dilution fluid inletor the perforator.
 19. The method of claim 1, further comprising one ormore of: detecting a temperature of the food or beverage liquid productat the product outlet, measuring a pressure of the food or beverageliquid product at the product outlet, or detecting a flow of the food orbeverage liquid product at the product outlet.
 20. A method forproducing a food or beverage liquid product from a frozen contents in areceptacle comprising: receiving a receptacle in a chamber of adispenser, the receptacle defining an enclosed inner volume containing afrozen liquid contents; perforating the receptacle and removing at leasta portion of the frozen liquid contents from the receptacle into amelting vessel; perforating the receptacle using a perforator disposedat the second end of the chamber to form a product outlet from thereceptacle for a food or beverage liquid product; imparting motion tothe melting vessel that increases a residence time of liquid in themelting vessel relative to a residence time of liquid in the meltingvessel without the imparted motion; heating at least one of the meltingvessel or the frozen contents within the melting vessel using anon-diluting heater, wherein the non-diluting heater does not add liquidto an interior of the receptacle when held in the chamber or to aninterior of the melting vessel; and dispensing the food or beverageliquid product.
 21. The method of claim 20, wherein the non-dilutingheater is one or more of: a heater in contact with walls of the meltingvessel, a heater incorporated into walls of the melting vessel, a heaterspaced apart from walls of the melting vessel and configured to transmitenergy to at least one of the melting vessel or the frozen liquidcontents by one or more of radiation or convection, an electric heater,a heated gas generator, a heated liquid bath, an electromagneticradiation generator, a thermoelectric heater, a heated perforator, or achemical heater.